Sie sind auf Seite 1von 60

December 2015 / deskeng.

com

M
I
A
T
P

Special
Issue!

Design

O
LO

UT

Ferrari Takes a Victory Lap


With ANSYS

Victories by Ferrari. Simulation by ANSYS.


Realize Your Product Promise

Winners demand the best. Ferrari would know. It has one of the best
racing records the world over.
Using ANSYS simulation technology, Ferrari is realizing its product
promise by optimizing critical aspects of its race cars, like brake
cooling systems and full-body aerodynamics, to better handle the
twists and turns of the racing world.
Sounds like Ferrari is in the drivers seat.

Visit ANSYS.COM/Ferrari to learn how simulation software can help you realize your product promise.

THE NEW EPSON SURECOLOR T-SERIES

Produce a presentation-quality, color, D-size plot in 25 seconds*

Extreme print accuracy at resolutions up to 2880 x 1440 dpi

Advanced pigment ink technology for truly durable, full-color prints

High-capacity ink cartridges up to 700 mL for low printing cost

Single and Dual-roll models, with optional copy and scan capability

Epson SureColor T-Series


Starting at $2,945 Single Roll

*S peedsarebaseduponprintenginespeedonly.Totalthroughputtimesdependuponfactorssuchascomputer,filesize,printerresolution,inkcoverage,andnetworking.Forthe
SC-T3270,fastestprintspeedforaD-sizeplotis28seconds.EPSONandSureColorareregisteredtrademarksandEPSONExceedYourVisionisaregisteredlogomarkofSeiko
EpsonCorporation.AdobeandPostScriptareeitherregisteredtrademarksortrademarksofAdobeSystemsIncorporatedintheUnitedStatesand/orothercountries.Copyright
2014EpsonAmerica,Inc.
Estimatedstreetpriceafterinstantrebateanddealerdiscount.Pleasevisitepson.com/prorebatesfordetails.CheckwithanEpsonProfessionalImagingAuthorizedResellerfor
actualprice,asdealerpricesmayvary.

epson.com /plotterinfo

Degrees of Freedom

by Jamie J. Gooch

Optimal Design Challenges

ngineer and author Henry Petroski once wrote: Successful design is not the achievement of perfection but
the minimization and accommodation of imperfection.
I like that. It rings true with a practicality missing in the
relentless pursuit of perfection mantras you hear in commercials.
A successful design is the optimal design for a given set of
constraints and requirements. Among those constraints are often
time and money. In fact, when asked to rank challenges to their
day-to-day workflow, the nearly 900 DE readers who responded
to our 2015 Reader Profile survey chose short development
deadlines and inadequate budgets at their second- and thirdmost extremely important challenges. Thats why bringing
more technology to bear sooner in the design cycle is so critical.
Simulation, optimization and real-time rendering all accelerated by increasingly powerful computing pays dividends in
time and cost savings when theyre performed early and often.
Likewise, 3D printing for prototyping and under increasingly
expanding circumstances end use parts, removes time and cost
from product development, testing and manufacturing.

A successful design is the optimal


design for a given set of constraints
and requirements.
But, perhaps surprisingly, collaboration ranked a bit higher
than challenges associated with time and budgets on our readership survey. Plus, inefficient workflows, a challenge that combines both time and collaboration issues, moved into the top
five extremely important challenge rankings.

Collaboration a Cause for Concern

As products become more complex and connected, designers,


mechanical engineers, electrical engineers and software developers who are often dispersed across the globe need to
work together more closely than ever to quickly get optimal
products manufactured and to market. Its the market that ultimately determines whether a product is successful, so executives
and marketing colleagues need to be brought into the product
development cycle as early as possible to ensure all your design
and engineering efforts arent for not. And those go-to-market
decisions are influenced by consumers ever-changing wants
and needs, which makes collecting, filtering, analyzing and incorporating usage data back into a design a top priority. That
data can also be used to alert engineers to service records and
part failures that can point toward design improvements.
The flow of information around the product development

DE | Technology for Optimal Design Engineering

IMPORTANCE TO DE READERS
COLLABORATION

62%

SHORT DEVELOPMENT DEADLINES

58%

INADEQUATE BUDGET

57%

REGULATORY COMPLIANCE
INEFFICIENCT WORKFLOWS
0

10

20

30

40

54%
53%
50

60

DEs 2015 Reader Profile survey revealed the importance of collaboration, with 62% of respondents ranking it as extremely important to their day-to-day work.
cycle and up and down the supply chain has been the subject
of many nice flowcharts, but in the real world its not so neatly
done. Creating a product development platform or system that
reaches across disciplines and industries, and integrates with
other information management systems to keep everyone properly informed is no small feat. Just sifting through the data
especially the increased amount of data expected to come from
the Internet of Things and Industrial Internet in the near future
is a daunting challenge.

Optimal Design Technology Outlook

This year-end edition of DE addresses what we see as some of


the top challenges facing design engineers in 2016, including
expanding the use of optimization technologies, attempts to
structure an approach to collaboration, combining real-world
data with digital design processes, designing products for the
Industrial Internet and consumer IoT, using 3D printing to
achieve more design freedom, and more. These arent far-off,
future technologies; theyre being used today.
As the philosopher Jeremy Bentham put it: The age we live
in is a busy age; in which knowledge is rapidly advancing towards perfection. That seems like an apt description of todays
product development cycle, but he wrote that in 1776. It was,
and is, a busy age, but our knowledge is still short of perfection.
Until then, we can use technology to minimize and accommodate imperfection to create optimal designs. DE

Jamie Gooch is the editorial director of Desktop Engineering.


Contact him at de-editors@deskeng.com.

December 2015 /// deskeng.com

Heavyweight simulation.
Lightweight parts.

Achieving your program goals of lighter, stronger designs in less time just got a little easier.
HyperWorks and solidThinking Inspire have been enhanced with new capabilities created

specifically for the aerospace industry, including more modeling control, greater analysis power
and the optimization leadership you expect from Altair.

Learn more at altair.com/aero


I N N OVAT I O N I N T E L L I G E N C E

December 2015

VOLUME 21/ISSUE 3

MA
I
T
P

SPECIAL
ISSUE!

34 Getting on Board with the

Design

By Michael Belfiore

42 Intelligence and the

Connected Car

LO O

Networking, software and


powerful processors continue
to transform our primary mode
of transportation.

UT

Industrial Internet of Things

Although the Industrial Internet of


Things, or IIoT, is still in its infancy,
standards and best practices for
security and interoperability are
already emerging.

By Peter Varhol

FOCUS ON OPTIMAL DESIGN

45 3D Printing Clocks In

12 End-to-End Engineering

Additive manufacturing will be a


part of more shop floors in the
future, and it will change the
design for manufacturing process.

By Bruce Jenkins

48 The Dawn of

Design explortion and optimization strategies


expand the benefits of simulation.

By Brian Albright

18 End-to-End Engineering

Does the shifting of


CAD licensing signal the
beginning of a new era?

Pay-As-You-Go CAD

Comprehensive platforms
let users design,
simulate and manage
a project from one
software suite, but they
also raise concerns.

By Kenneth Wong

52 Learning to
Use the Black Box
Correctly

By Jess Lulka

24 Avatars Land a Role in Product Design


The concept of a digital twin is gaining traction as
companies look at connecting the physical product
to its virtual counterpart.

Professors and employers


discuss the role of software
in STEM education.
By Kenneth Wong

By Beth Stackpole

SPECIAL SECTION
27 Optimal Design Leaders

Cover image: Thinkstock

DE | Technology for Optimal Design Engineering

See how this sections sponsors, BOXX


Technologies, CD-adapco, COMSOL, Dassault
Systmes SIMULIA, ESTECO and Rave
Computer optimize the product design and
development process in their own words.

December 2015 /// deskeng.com

OPTIMAL
DESIGN
LEADERS

DEPARTMENTS
2 Degrees of Freedom
Optimal design challenges.
By Jamie J. Gooch

6 Virtual Desktop

Jon Peddie Research looks at


virtualization adoption, PTC gets into
augmented reality, Autodesk debuts
Shape Generator and MathWorks helps
the Carnegie Wave Project.
By Kenneth Wong and Beth Stackpole

10 On The Road

DE travels to Euromold 2015, GPDIS,


COMSOL Conference Boston, Graebert
and Bricsys user meetings, Siemens
Industry Analyst Conference and
Autodesk Accelerate 2015.

51 Spotlight

Directing your search to the companies


that have what you need.

54 Editors Picks

Products that have grabbed the


editors attention.
By Anthony J. Lockwood

55 Fast Apps

9 Rapid Ready Tech

NASA simulates Orions heat shield


with CFD software and an EmbryRiddle student uses DFMA to design
a sport vehicle attachment.

Avi Reichental departs from 3D


Systems, Local Motors debuts its roadready car, Canon enters the 3D printing market and Stratasys invests in
desktop metal 3D printing.

PUBLISHER
Tom Cooney
EDITORIAL
Jamie J. Gooch | Editorial Director
Kenneth Wong | Senior Editor
Anthony J. Lockwood | Editor at Large
Jess Lulka | Associate Editor
Sarah Petrie | Copy Editor
CONTRIBUTING EDITORS
Tony Abbey, Brian Albright, Michael Belfiore, Mark
Clarkson, David S. Cohn, John Newman,
Beth Stackpole, Peter Varhol, Pamela J. Waterman
ADVERTISING SALES
Chuck Curley | East Coast Sales 508-663-1500 (x498)
Chris Casey | Midwest/West Coast Sales 847-274-5476
ART & PRODUCTION
Darlene Sweeney | Director darlene@deskeng.com
A PEERLESS MEDIA, LLC PUBLICATION
Brian Ceraolo | President and Group Publisher
ADVERTISING, BUSINESS, & EDITORIAL OFFICES
Desktop Engineering magazine
Peerless Media, LLC
111 Speen St., Suite 200, Framingham, MA 01701

Phone: 508-663-1500
E-mail: DE-Editors@deskeng.com
www.deskeng.com

www.peerlessmedia.com

55 Advertising Index

Kenneth Moyes | President and CEO, EH Publishing, Inc.

56 Commentary

SUBSCRIBER CUSTOMER SERVICE


Desktop Engineering magazine
PO Box 677 Northbrook, IL 60065-0677
Phone: 847-559-7581 Fax: 847-564-9453
E-mail: den@omeda.com

Design smart home services, not


connected things
By Cees Links, GreenPeak

38 The Design Engineers

Desktop Engineering (ISSN 1085-0422) is published


monthly by Peerless Media, LLC, a division of
EH Publishing, Inc. 111 Speen St., Suite 200 Framingham,
MA 01701. Periodicals postage paid at Framingham, MA
and additional mailing offices. Desktop Engineering is
distributed free to qualified U.S. subscribers.
SUBSCRIPTION RATES: for non-qualified; U.S. $108
one year; Canada and Mexico $126 one year; all other
countries $195 one year.

High-Performance Computing
Handbook

Send all subscription inquiries to Desktop Engineering


111 Speen St., Suite 200, Framingham, MA 01701

The HPC Handbook is a new, multimedia resource


produced by DE in partnership with Intel that
takes a detailed look at computing topics that are
important to design engineers.

LIST RENTALS: For information on list rentals, contact


Statlistics, Danbury, CT. Phone: 203-778-8700.
Postmaster: Send all address changes to Desktop
Engineering, PO Box 1496 Framingham, MA 017011496. Reproduction of this magazine in whole or part
without written permission of the publisher is prohibited.
All rights reserved 2015 Peerless Media, LLC.

The HPC Handbook consists of:


Magazine article excerpts;
The hpc.deskeng.com website; and
Regularly released chapters that are free
to download.

Address all editorial correspondence to the Editor,


Desktop Engineering. Opinions expressed by the authors
are not necessarily those of Desktop Engineering.
Unaccepted manuscripts will be returned if accompanied
by a self-addressed envelope with sufficient first-class
postage. Not responsible for lost manuscripts or photos.

Visit hpc.deskeng.com to download the


latest chapters in The Design Engineers
High-Performance Computing Handbook!

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

Virtual Desktop

by Kenneth Wong & Beth Stackpole

Courting the Dedicated Workstation Users

he devout workstation users are


the last stronghold that virtualization vendors have been trying to breach. Others general consumers, knowledge workers and
enterprise software users have already
embraced the freedom that comes with
mobile devices and tablet clients. But the
workstation crowd is different.
At Octobers Jon Peddie Research
(JPR) Virtualize Conference, in a session devoted to Best Practices for Large
and Small Companies, Gary Radburn,
Director of Workstation Virtualization
at Dell, observed, [Workstation users]
are very proud of their workstations. A
workstation-using engineer feels valued
by the size of the box, the memory and the
GPU (graphics processing unit) in it. If
you change that with a thin client without
telling them, theyd probably be upset.
The success of the campaign, as it
turned out, depends as much on psychology as it does on technology. Involve the
users from day one. Dont suddenly go in
there and, thinking youre doing them a
favor, replace whats on their desk [with
a thin client device]. Youre trying to
increase productivity, not to destroy their
morale, Radburn said.

Virtualization Knowledge

JPR recently published Virtualization


and Remote Graphics: A Special Report
on the Users and Potential Users of
Virtualized Systems, based on survey responses from 350 participants. The goal,
JPR states, is to determine if the [senior]
managers knew about virtualization, had
tried it, or were planning to try it.
Remote graphics graphics features
generally available in physical GPUs
made available remotely to virtual
machines is a critical issue in virtualization adoption among design and
engineering software users who rely
on digital prototypes to make critical
decisions. If the quality of the visuals
on virtual machines is not comparable
to what the users are accustomed to on

DE | Technology for Optimal Design Engineering

2% Not Stated
20% Neutral
30% Quite Interesting

22% Dont Know, Misc.


26% Very Interesting
Interest in access to an office workstation on the road, as indicated by survey
results from JPR, published in Virtualization and Remote Graphics, a special
report on the users and potential users of virtualized systems.
Image courtesy of Jon Peddie Research.
physical workstations, theyll most likely
reject virtualization as a poor substitute
for real workstations.
Survey responses suggest NVIDIA
is leading the awareness campaign.
Twenty-five percent say they are aware
of the NVIDIA GRID virtualization
solution. Fifteen percent are aware of
offerings from Citrix, and 9% of those
from Intel. More than a third 33%
indicate theyre not aware of any, suggesting providers need to do a better job
with outreach and awareness campaigns.
Respondents also give virtualization
vendors some encouraging signs. More
than 70% think remote access to their
office workstation from home is quite
interesting, and more than 50% think
its very interesting. Similarly, more
than 60% say remote access to an office workstation from the road is quite
interesting, and more than 50% think
its very interesting. The survey also
asks respondents to give a reason if they
indicate theyre not interested in remote
workstation access. The biggest reason
for not adopting virtualization is listed as
no productivity gain, according to JPR.
When asked, If you were to employ
December 2015 /// deskeng.com

remote graphics would it be for all of


your applications or just one? 32% say
for all, 27% for one. The remaining
41% say they dont know. But a whopping 52% indicate that theyre aware
that GPUs could be shared in a virtualized setup a key benefit of virtualization. An overwhelming 75% believe
there is, or will be a benefit to using a
virtualized GPU/workstation.
By and large, IT departments are the
gatekeepers that virtualization vendors
have to convince. Thirty-one percent
of the respondents reveal theyll acquire
virtualized systems from their IT. Only
8% say theyll get it directly from the
supplier. Only a fraction say theyll turn
to systems integrators, VARs (value
added resellers) and software providers.

Benchmarking Performance

At the conference, SPEC (Standard Performance Evaluation Corporation) led


a panel discussion titled Benchmarking
Virtualized Processors. The session
sought to find out the truth in claims
being made about performance, according to the organizers. Many workstation makers regularly cite SPECview-

perf scores as the hallmark of quality in


their hardware. As custodians of widely
adopted performance benchmarks,
SPEC plays a role in establishing a set
of fair, reasonable standards for assessing
the capacity of virtual machines.
SPEC maintains the SPECvirt
benchmark for evaluating virtualized
data centers. It measures the end-toend performance of all system components including the hardware, virtualization platform, and the virtualized
guest operating system and application
software, according to SPEC.
SPECvirt supports hardware virtualization, operating system virtualization, and hardware partitioning schemes.
The SPEC workstation benchmark,
SPECwpc, also measures virtualization
based on specific business and industrial
applications, as does SPECviewperf for
graphics-intensive applications. The
recently introduced SPECjbb2015 also
supports performance measurement for
virtualized hosts, said Bob Cramblitt,
PR spokesperson for SPEC.
Because GPU sharing is one of the
economic benefits of virtualization, the
latency, interactivity and photorealism
associated with virtual machines is expected to be a major factor shaping the
users experience. No conclusion was
reached [by the panelists] other than to
acknowledge that this is going to be a
thorny and probably contentious issue,
but one that has to be dealt with, said
Kathleen Maher, vice president of JPR.
Dells Radburn offers an argument
he thinks will persuade the workstation users to relinquish their cherished
hardware: Point outside their window
the sales and marketing folks working
in coffee shops, fields and beaches,
then say, Wouldnt you like a slice of
that life?
We think that virtualization is the
next step, and a very big one towards
making the technology invisible. Normal humans were not born to become
IT experts when they want to communicate with their friends, do their jobs or
create art, said Maher.
K. Wong

PTC Gets Real With


Augmented Reality

n its latest move, PTC signed a


definitive agreement to buy the Vuforia augmented reality business for
$65 million, including its developer
ecosystem, from Qualcomm Connected
Experiences Inc., which is a subsidiary of
the mobile giant Qualcomm. As it exists
today, Vuforia is a mobile vision platform
that currently has traction in the consumer world, helping to bring advertisements, toys and household items to life
on a smartphone or tablet.
PTCs vision for Vuforia is to bridge
the digital and physical worlds, a reality
that PTC executives say is increasingly
blurring as todays products meld both
digital and physical components. If you
look at whats going on in manufacturing companies today, the BOM (bill
of materials) is very different than its
historically been, and theres a lot more
decisions about what lives in a digital
form or what lives in a physical form,
says Rob Gremley, executive vice president, Technology Platforms at PTC.
This whole mixed reality of the digital
and physical living together has been a
big theme of what were doing.

A Mixed-Reality Model

With the Vuforia augmented reality


technology, engineering organizations
can gain access to digital information that
exists about a product in particular, the
sensor data that depicts whats happening
with a product in the field alongside
the physical product. This capability,
bolstered with PTCs IoT (Internet of
Things) and analytics platforms, unlocks
new possibilities for designing products,
monitoring and controlling products and
facilitating service in the field.
By integrating Vuforia into the
ThingWorx IoT platform, PTC plans
to facilitate a mixed-reality model that
blends the physical and digital worlds.
deskeng.com /// December 2015

As an augmented reality technology,


Vuforia will help PTC bridge the
digital and physical worlds.
Image courtesy of Vuforia.
Itcan be used as a foundation to enable
new applications and ways of working
for both service and product design.
Today, interaction with either the physical product or digital representation of
that product is separate, but PTC aims
to bring its technology portfolio to bear
to deliver a mixed reality experience for
interacting with those same representations, said PTC CEO Jim Heppelmann,
in a webcast that highlighted PTCs
plans for the acquisition.
When you put augmented reality
together with the other critical technologies weve acquired, it represents a new
platform for the new reality of physical/
digital convergence, he said, adding
that PTC has invested over $600 million in the last 24 months to bring that
vision to life, through both acquisition
and organic development.
Beyond the Vuforia computer vision technology, PTC sees opportunity
in the companys global developer
ecosystem, currently the source for
20,000 augmented reality applications,
representing about 76% of that market,
Heppelmann said. Vuforia is a gem that
needs to be unlocked and exposed to a
broader audience, and thats something
PTC is in a position to do, he said.
B. Stackpole
DE | Technology for Optimal Design Engineering

Virtual Desktop

by Kenneth Wong & Beth Stackpole

MBD Energizes Wave Farm

5 system, Carnegie Wave Energy engineers needed insight into multiple variables, including how much load could be
placed on the systems mechanical components so they could be sized properly.
A design that incorporated components
that were too strong or heavy would
result in additional costs, while planning
the system with less-than-robust components would put it at risk for failure in
stormy seas. Building out a scale model of
the entire system was not feasible so the
team opted for a Model-Based Design
(MBD) approach that would support a
multidomain system along with simulations to explore a range of configurations,
sea conditions, and faults.
Harnessing MathWorks MATLAB
and Simulink MBD tools, Carnegie
Wave Energy was able to iterate and test
virtual prototypes of the CETO 5 design
as opposed to building physical prototypes. It allowed the team to demonstrate
the ability of a small CETO 5 array to

hen youre designing


something as groundbreaking and massive as
the worlds first and only
operating wave farm, building a physical prototype is out of the question for a
whole multitude of reasons, not the least
of which is cost and scale.
Thats the situation Carnegie Wave
Energy faced during the design of
CETO 5, technology that generates
power from ocean swells using submerged buoys. CETO 5 is a cornerstone
of the Perth Wave Energy Project
(PWEP), which is currently the worlds
only operating grid-connected wave
energy array. CETO 5 is a multidisciplinary system, converting hydrodynamic forces from the ocean to mechanical energy by the motion of the buoy,
then to hydraulic energy through use of
a pump, and finally to electrical energy
using hydroelectric conversion devices.
Before physically building the CETO

Carnegie Wave Energys CETO unit is the


foundation for the grid connected Perth
Wave Energy Project. Image courtesy of
Carnegie Wave Energy.
produce and sell power reliably while also
verifying the accuracy of the computational CETO system model against the
measured project performance, according
to Mathieu Cocho, analysis engineer at
Carnegie Wave Energy.
B. Stackpole

Shape Generator Makes its Debut

ts a vision that Autodesk CTO Jeff


Kowalski shared a year ago. Inside
the Mandalay Bay hotel, speaking
to the crowd at Autodesk University 2014, Kowalski said, [It] starts
with your goal. Then it explores all the
possible permutations of the solution
through successive generations, until the
best one is found. That sums up what
Autodesk calls generative design.
A variant of generative design can
be seen in Autodesk Within, which automatically generates lattice structures
that fit user-defined geometric volumes.
Another variant appears in the latest
update to Autodesk Inventor as Shape
Generator, a topology optimization
function embedded in Inventors CAD
modeling environment.
Like Autodesk Within, Shape Gen-

erator relies on Autodesk Nastran as


its simulation engine to perform stress
analysis behind the scenes, then proposes the best or optimal geometry for the project.
Whats different about this is, its
integrated into a mainstream CAD
platform, says Jonathan den Hartog, an
Autodesk product manager for Autodesk
Inventor. Our approach is to put it in
CAD so it can benefit the conceptual
design phase.
Special software like solidThinking Inspire lets you perform topology
optimization. Certain simulation and
analysis packages also offer the function. However, its rarely integrated in
general-purpose CAD programs. In
that respect, Autodesk Inventor may be
breaking new ground with the introduc-

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

tion of Shape Generator. Introducing


optimization at the CAD design phase
brings the art of lightweighting closer
to the conceptual design phase. In the
initial incarnation, Shape Generator
focuses on structurally efficient lightweight parts, explains Hartog.
Since Shape Generator is embedded
inside Inventor, the user can overlay
optimized geometry proposed by the
software to the original part, making it
easier to identify the regions where further trims and cuts can be made without
affecting the parts structural integrity.
The way Shape Generator works is consistent with the way youd use topology
optimization in specialized CAE software, but with a simpler interface.
For more information, see page 12.
K. Wong

Making Digital Designs Physical

Avi Reichental Departs


3D Systems

3D Systems (3DS)
has announced
the departure of
Avi Reichental,
who was president,
CEO and a director
of the company.
Reichentals
departure comes on the heels of a
serious downturn in 3DS share price,
and amid various lawsuits targeting
the company, some of which name
Reichental directly.
Although it seems likely that a large
drop in 3DS stock share price could
have resulted in Reichentals departure,
other factors may also have played a
role. A group of shareholders expressed
their dissatisfaction with 3DS and
Reichentals leadership with the launch
of a lawsuit in August. The suit claimed
that Reichental and other members of
3DSs leadership had overestimated the
companys ability to fulfill printer orders,
leading to a loss in profits.

MORE rapidreadytech.com/?p=9539

Stratasys Invests in
Desktop Metal

Stratasys was recently part of a group of


investors backing a new startup called
Desktop Metal. The company has $14
million in funding and the stated goal of
producing a desktop metal AM system
that can run in an office space with no
muss or fuss.
Desktop Metal is led by CEO and
co-founder Ric Fulop, who has been
involved with a number of other
companies, including MarkForged,
developer of a 3D printer that can
produce carbon fiber parts. Fulop said
he believes AM is still in its infancy,
and that metal AM is one area lacking
serious progress that would allow for a
wider scale adoption.

Rapid Ready Tech

Local Motors Debuts LM3D

ocal Motors has been wowing the


tech world with its 3D-printed vehicle
concepts. It printed an entire Strati at several
different conferences over the past two years,
and now its showing off the LM3D Swim
vehicle, which was on display at the Specialty
Equipment Market Association (SEMA) 2015
show in November.
Unlike the Strati, the LM3D is now undergoing crash testing as part of Local
Motors efforts to create a road-ready 3D-printed car for release in 2017. The
estimated retail price for the car will be around $53,000, not including special
subsidies for electric vehicles. The design for the LM3D emerged out of the Project
REDACTED challenge. Kevin Lo submitted the winning design (which was modified
by the Local Motors team), and the first model was produced just a few months later.
Local Motors used Siemens Solid Edge for product development, and printed the
vehicles using materials from SABIC.

MORE rapidreadytech.com/?p=9560

Recording Shipwrecks
with 3D Technology

Part of the University of North


Carolina Coastal Studies Institutes
mandate is to preserve and record
shipwrecks wherever they are found,
both on land and in the sea. Generally,
a shipwreck that washes ashore faces
destruction both from the pounding of the
waves and the slow drying out process
that leeches preserving water from the
structure. In the past, UNC teams have
had to race against the clock to capture
images of beached wrecks, but advances
in 3D technology have made documenting
such finds easier and faster.
In 2009, winter storms uncovered
the remains of a ship built in the 1600s.
Rather than leave the find to be destroyed
by the elements, UNC removed the wreck
from the beach. The drying out process
left behind a mass of twisted lumber that

MORE rapidreadytech.com/?p=9545

can only vaguely be recognized as a ship


and left UNC with a desire for a better
method of recording the past.

MORE rapidreadytech.com/?p=9551

Canon to Enter 3D
Printing Market

During the Canon Expo held in Paris, the


company revealed plans to enter the 3D
printing market with a brand new system
developed internally. While the actual
printer wasnt on display, Canon showed
off parts built by the prototype system,
and discussed some of what it hopes to
accomplish.
Canon says it would employ a new
(unspecified) additive manufacturing
process based on general use resins
to offer customers material diversity.
According to the company, its 3D
printer will reduce post-processing
requirements, and include water
soluble support material.
The company wants to create an
entire digital environment with what it
calls a 3D Integrated Software solution.
This includes 3D scanners, AM systems
and digital design tools.

MORE rapidreadytech.com/?p=9499

For more coverage of rapid technologies, visit RapidReadyTech.com


deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

On The Road

Engineering Conference Coverage

Democratizing Simulation Digital Disruption


COMSOL Conference Boston 2015 gave
attendees a first-hand look at some of
the softwares new features, a host of use
cases and the chance to directly provide
feedback on its Multiphysics platform.
The company also offered plenty of
traditional and on-hands learning courses
with a pre-release of version 5.2.
In 2014, COMSOL introduced
the Application Builder and Server to the
simulation community with Multiphysics
5.0. This year, the company has been
working to make Application Builder and
Servers main capabilities more robust
and accessible to users. The goal is to be
able to provide Multiphysics modeling
and simulation to everyone, according to
Svante Littmarck, CEO of COMSOL.

MORE deskeng.com/de/?p=26730

A New Product Lifecycle

At this years Autodesk Accelerate


conference, presenters and attendees
made good use of buzzwords as they
predicted The Future of Making
Things. With the emergence of smart,
connected devices and the shift to
a service-oriented economy, its no
secret that the way engineers design
products is rapidly changing. But how
does this new design process fit into
current practices, such as PLM (product
lifecycle management)?
In his keynote, Scott Reese, VP of Cloud
Platforms at Autodesk, said, Were seeing
a lot of disruption, a greater amount than
weve ever seen ... Were seeing the little
guys take on the big guys. Reese also
cited Big Data and smart products as
contributors to disruption.

MORE deskeng.com/virtual_
desktop/?p=10859

his year, Siemens PLM Softwares main strategy


could be summed up in one word: digitalization. The
fact that the virtual world is colliding with the physical
world is nothing new. What is new to some is the
disruption the shockwaves of that collision are causing
to every aspect of the enterprise.
Unlike its competitors, Siemens PLM Software is owned
by the largest engineering company in Europe, Siemens AG. The multi-national parent
has hundreds of production and manufacturing facilities, including what it calls
lighthouse plants in Germany and China that are highly automated. Siemens PLM
Software took advantage of that expertise at this years Industry Analyst Conference
by inviting Dr. Horst J. Kayser, chief strategy officer, Siemens AG to keynote.

MORE deskeng.com/virtual_desktop/?p=10889

Casting a Positive Global


Vision for 3D Printing

Speakers at this years 17th annual


International Wohlers Conference and
Euromold Exhibition took on the state
of 3D printing, as its stockmarket prices
were taking a beating.
Keynote speaker and Autodesk CTO
Jeff Kowalski said the biggest changes will
not come from the 3D printers, but from
the software used to design products and
provide the data to the printers.

MORE deskeng.com/de/?p=26315

AutoCAD Alternatives

Autodesk remains the market


leader for 2D product design and
manufacturing, but it is not the only
player. Two developer conferences held
in Germany brought together a range
of small third-party developers and a
few well-known brands that share a
common interest in supporting the DWGcompatible CAD market independent of
Autodesk. Graebert Software and Bricsys
both create software that supports the
DWG format popularized by Autodesk.
Graebert is a CAD vendor that some
might say has an identity problem. There
are more than 1 million active users of
its software, yet only a small percentage
knows the vendor behind it. Most of
them are SOLIDWORKS and CATIA users
who take advantage of free or paid

For more engineering conference coverage, visit deskeng.com


10

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

versions of DraftSight CAD distributed


by Dassault Systmes.
Bricsys believes the continued impact
of Autodesks bifurcated strategy has
given it an opportunity. Bricsys has
built an international dealer network by
being the core CAD engine for 1,200
development partners who create
hundreds of genre products, such as
mechanical modelers in most European
languages, plant design software and
many products for AEC (architecture,
engineering and construction) and GIS
(geographic information systems).

MORE deskeng.com/de/?p=26955

Automation in Aerospace

This years Global Product Data


Interoperability Summit (GPDIS) 2015,
had a leading-edge something for
everyone. The event covered modelbased manufacturing, the factory of the
future, wearables, sensors, cloud topics
and, of course, standards.
Jay Ganguli from The Boeing Company
was the first of many presenters to
update attendees with ongoing standards
committees activities including the
implications of some of the current
directions. He notes that future influential
and disruptive activities include the
Internet of Things (IoT), Industrial Internet
and Industry 4.0.

MORE deskeng.com/virtual_
desktop/?p=11083

BOXX Technologies Sponsored Report

/// Engineering Computing

A Crash Course in
Workstation Configuration
C

onfiguring the ideal workstation for your specific workflow can be a daunting task. With that in mind, BOXX
Technologies has assembled a mini buyers guide designed to help engineers sort through processor, GPU and hard
drive configurations, and make a custom workstation match.

Processor Cores and Threads vs. Frequency

Aside from budget constraints, the most significant consideration is CPU cores specifically, how fast and how many.
Modern workstations range from four to up to 18 cores, and
many include hyper threading, which theoretically doubles
the systems ability to process threads (but does not double
its performance).
Frequency-bound applications, including 3D modeling
tools like SOLIDWORKS or Autodesk 3ds Max, benefit from
CPU frequency more than cores. Thats why BOXX offers safe
overclocking, which provides up to 25% more performance
by unlocking the built-in frequency headroom found inside
Intel CPUs. Our maximum frequency workstation is APEXX
2 Model 2401.
Highly threaded applications, such as rendering or simulation, can benefit from multiple cores, thus we recommend Intel
Xeon processors with high thread counts such as the APEXX
4 Model 7901. If a workflow requires both higher frequencies
for interactive activities and high thread counts for rendering
or simulation, the optimal solution would be to combine an
APEXX 1 Model 1401 with a BOXX renderPRO 1, a desk-side
rendering and simulation solution.

The GPU

The graphics processing unit (GPU) is primarily responsible


for what you see on your screen. GPUs come in a variety of
flavors from NVIDIA and AMD. 3D design and modeling applications rely on the GPU to keep frame rates up for smooth
panning, zooming and rotating when creating and manipulating
3D objects. However, these applications are frequency bound
and cant take advantage of multiple GPUs. For good viewport
performance in these applications, we recommend a minimum
configuration of an NVIDIA Quadro K1200 GPU
For certain rendering and simulation applications, the GPU
can work in the background, operating exponentially faster than
a CPU. Examples include GPU rendering engines like V-Ray
RT, Iray or Octane, and simulation applications such as CATIA

or ANSYS. In most of these cases, higher end GPUs will result


in linear performance gains.

Hard Drives

The unsung hero in system responsiveness is a workstations


storage technology. While the basic functionality of mechanical
hard drives hasnt changed in over a half century, the technology used to increase performance and storage size has evolved,
all while delivering smaller and more innovative form factors.
Despite such advancements as migration from Parallel ATA
(PATA) to Serial ATA (SATA) and new technologies like Native Command Queueing, onboard caching, faster on-board
processing, denser platters and increased spindle speeds, the
mechanical hard drive still has inherent limitations that can be
detrimental to your workflow.
Its safe to assume that all solid-state drive products (especially
the Intel 750 SSD) will outperform mechanical drives in booting up a system, opening programs and any other bandwidthintensive applications. Mechanical drives are only recommended
for storing and archiving data and not for active projects.

RAM

Open up your task manager and look at your RAM usage while
working. If during your most intensive tasks, youre not coming
within 30% of the maximum RAM amount, youre probably
in a safe range. However, more RAM means more room for
multitasking, so investing in additional memory can be beneficial to your overall workflow. The minimum recommendation
is for 16GB of RAM, while large data sets for simulation, large
scenes with lots of polygons and textures, and complex parts in
engineering applications will benefit from additional memory.
For an in-depth version of the BOXX guide, click here:
www.boxxtech.com/DEhardwareguide.

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

11

Focus on Optimal Design /// Optimization

Find the Optimal Design

Design exploration and optimization strategies expand the benefits of simulation.


BY BRUCE JENKINS

ecognizing the largely untapped


value of digital simulation in new
product development, more and
more engineering organizations are leveraging their existing CAE assets with
new, complementary investments in design space exploration and design optimization technologies and methods
that automatically exercise simulation,
analysis and modeling applications to rationally and rapidly search through large
numbers of design alternatives to identify
the best possible designs.
These technologies began much the
same as CAE, used chiefly by an elite
group of experts for their most critical
problems. But today, advances in usability, off-the-shelf connectors to all widely
used modelers and solvers, and built-in
(or easily captured) knowledge that guards
against errors and misinterpretation of
results are transforming these tools into
practical, everyday engineering aids.

Topology Optimization Boosted


by Additive Manufacturing

Of the technologies available for automated design exploration and optimization, the most widely used is likely structural optimization. Applying algorithms
to solve structural problems by means of
finite element analysis (FEA), this software optimizes some aspect of a products
geometry most often topology, shape,
size, topometry or topography to satisfy
operating limits imposed on the response
of the structure, and limits on the values
that the structural parameters can assume.
Among the different kinds of structural optimization, topology optimization
is currently the focus of greatest effort by
software vendors to make it more accessible and easily applied by non-specialists.
An important driver of efforts to
make topology optimization accessible

12

solidThinking Inspire 2015 supports assembly optimization. Image


courtesy of solidThinking
to as many users as possible is the surge
of activity around additive manufacturing. Often used to identify a conceptual
design that best meets specified design
requirements, topology optimization
works by optimizing material layout
within a given physical design volume
for a specified set of loads and boundary
conditions, so that the resulting layout
meets prescribed performance targets. It
frequently yields biomorphic-like shapes
suited to additive manufacturing. These
can then be modified for production by
conventional subtractive manufacturing,
if required.

Autodesk Within Generates


Lightweight Designs

One vendor leading the move to democratize topology optimization is Autodesk.


Autodesk Within, released in July 2015,
is a set of generative design software solutions to help engineers create and 3D
print lightweight designs for the automotive, aerospace, industrial equipment and
medical implant industries. Generative
design, advances in material science, and

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

new fabrication techniques are allowing


engineers to deliver components that were
never before possible. Autodesk Within
enables designers to create high-performing parts while enforcing design rules and
adhering to additive manufacturing constraints, says Mark Davis, senior director
of Design Research at Autodesk.
Based on technology from Autodesks
2014 acquisition of London-based
Within Lab, Autodesk Within is built
around an optimization engine that takes
input parameters such as desired weight
requirements, and maximum stress and
displacement, then generates designs
with variable-density lattice structures
and surface skins to meet those specifications. The aim is to produce components
that are both more high performance and
lightweight, which are then refined for
production by additive manufacturing.

Shape Generator Integrates


Topology Optimization into Inventor

Another Autodesk initiative is Shape


Generator, a new feature in Autodesk Inventor 2016 R2 (released October 2015)

that provides topology optimization integrated directly into Inventor. Shape


Generator is a conceptual design tool
that generates a lightweight, structurally
efficient 3D shape in response to a specified load case, using finite element methods to optimize material for the defined
criteria. The user specifies boundary
conditions, loads and target, then Shape
Generator generates a 3D shape that can
be used as a conceptual guide for preliminary design of a lightweight part.
Autodesk says that over time, generative design features will be incorporated
into still more of its software portfolio.
Much of this technology will come from
Project Dreamcatcher, an initiative by
the Autodesk Research organization to
explore and expand the limits of generative design using cloud computing,
natural-language input, pattern-based
problem description and AI-assisted design space visualization.

ers and engineers develop lightweight


and structurally efficient designs. Recent
releases offer novel solutions for design
and optimization of 3D printed lattice
structures and advanced materials such
as laminate composites.
In keeping with OptiStructs 20-year
history of introducing new capabilities,

of the industrys longest-established solutions for structural design and optimization. A structural analysis solver for linear and nonlinear problems under static
and dynamic loadings, OptiStruct uses
finite element and multibody dynamics
technology, together with analysis and
optimization algorithms, to help design-

NEW VERSION!

Inspire 2015 Expands Structural


Optimization to Assembly Models

Another product bringing structural


optimization into conceptual design is
solidThinking Inspire from solidThinking Inc., an Altair company. This software
helps engineers, product designers and
architects create and investigate structurally efficient concepts quickly and easily.
solidThinking Inspire 2015, released
in June, significantly expanded the scope
and complexity of problems the software
can address. Most notably and unlike
many other volume-market optimization
solutions Inspire can now model, optimize and analyze product assemblies,
not just individual components. With
support for assembly optimization, users
can now incorporate a surrounding structure into their optimizations and gain a
deeper understanding of the relationship
between multiple components, says Andrew Bartels, program manager for solidThinking Inspire.

Over 100 new features &


improvements in Origin 2016!

FOR A FREE 60-DAY EVALUATION,


GO TO ORIGINLAB.COM/DEMO
AND ENTER CODE: 7853

OptiStruct Adds Lattice


Structures, Advanced Materials

Over 500,000 registered users


worldwide in:
6,000+ Companies including
120+ Fortune Global 500
6,500+ Colleges & Universities
3,000+ Government Agencies
& Research Labs

20+ years serving the scientific


& engineering community

In addition to solidThinking Inspire, Altair continues to advance OptiStruct, one


deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

13

Focus on Optimal Design /// Optimization

Shape Generator workflow: (1) Create a build volume or approximation of the


part model; specify requisite contact points such as the two pin locations and
the contact surface where force will be applied. (2) Specify preserve (keep out)
zones that will not be modified when creating the guide shape; apply constraints
and forces that the part may encounter in use. (3) Run a Shape Generator Study;
receive back a mesh in response to the criteria. (4) Use the mesh as a guide
for making modifications to the build volume model user edits transform the
model from an approximation into a design. Image courtesy of Autodesk.
new functionality in the recent 13.0 release includes support for poroelastic
(Biots equation) material properties,
large-displacement nonlinear analysis,
nonlinear heat transfer and more, according to the company.
The current OptiStruct 13.0.210 release features a new solution for design
and optimization of 3D-printed lattice
structures, which can provide design
concepts for a blended solid-and-lattice
structure or a lattice-only structure.
The lattice structure can be fine-tuned
through size optimization techniques to
meet various performance requirements.

zation (MDO), multi-objective (Pareto)


optimization and stochastic (robustness
and reliability) optimization.
A focus of development across the
industry is to make these tools easily and
safely usable without requiring expert
knowledge of the quantitative and algorithmic methods that underlie them. For
example, users long had to know a fair
amount about the array of statistical sampling methods to perform a DOE study
full factorial, fractional factorial, Latin
hypercube and others to choose one

best suited to the particular problem being


studied. In setting up complex multidisciplinary optimization runs, they needed
some understanding of gradient-based vs.
deterministic vs. heuristic solution methods, the issues involved in searching for
local vs. global optima, and more.
Today, developers are removing
these complexities by building in intelligence that lets their software make
more and more of these decisions autonomously, based on the users description of the problem in engineering
terms in effect, making design exploration software speak the language
of engineers and not mathematicians.
This is a prime focus of development
for Altairs HyperStudy, CD-adapcos
Red Cedar Technology HEEDS MDO
with its SHERPA search method, Dassault Systmes SIMULIA Isight and
the Design Optimization Roles in its
3DEXPERIENCE platform, ESTECOs modeFRONTIER with its new
pilOPT one-click self-adapting optimization algorithm, Exas PowerFLOW
Optimization Solution, Noesis Solutions Optimus with its new Adaptive
DOE techniques, and others.

Design Space Exploration Software


Speaks the Language of Engineers

Structural optimization is far from the


only area of progress in leveraging simulation with powerful layers of intelligent
automation that offer engineers more
complete, higher-fidelity visibility into
product performance earlier than was
possible with older approaches. Equally
important advances are coming in design
space exploration a category of software and methods that are beginning to
radically advance the capabilities of engineers and multidisciplinary engineering
teams to discover an array of feasible design concepts early; rapidly and fluently
evaluate sensitivities, variants, and tradeoffs; then select the best candidates and
optimize them. These include design of
experiments (DOE), parameter and sensitivity studies, multidisciplinary optimi-

14

Optimate+ is a CD-adapco STAR-CCM+ add-on that provides a scriptless


solution for automation of design exploration to help engineers set up,
execute and post-process design studies, which include parameter sweeps,
DOE and optimization using the SHERPA algorithm from within STAR-CCM+.
Image courtesy of CD-adapco.

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

MEASUREMENT COMPUTING

71%

Advanced
Data Logging
Application

of DE readers surveyed
strongly agree that design
optimization will revolutionize
the design process.

Measurements
in Minutes!

DE 2015 Reader Profile

Overcoming Market
Development Constraints

Despite these technological advances,


however, many more engineering organizations could be taking advantage
of design space exploration and design
optimization than do today. One reason is simply the constrained marketing
and sales resources of some of the small,
independent software developers that
make up much of this industry segment.
An example of what expanded market
development resources can accomplish
is Red Cedar Technology, which grew
its billings more than 80% and tripled
its customer base less than a year after its
2013 acquisition by CD-adapco.
Another constraint on adoption is that
design exploration and optimization are
not part of the standard work process at
enough engineering organizations today.
Too many still rely on intuition-based,
hit-or-miss engineering practices, not recognizing how these new technologies for
systematic, rational, software-enabled design discovery, exploration and optimization deliver benefits well beyond the costs
of bringing them into the organization.
A related constraint is that design exploration and optimization are too often
implemented at only the department or
workgroup level. To have the greatest impact, the technologies and attendant work
processes need to be recognized and given
backing as enterprise capabilities. Achieving adoption at the institutional level:
Eliminates burden of re-justifying tools
and methods on every new project.
Mitigates the problem of software and
work processes falling into disuse between projects.
Makes the technology more readily applicable across disciplines and domains
the wider this span, the greater its impact.
Fosters systems thinking across project

Easy to Use Easy to Integrate


Easy to Support

teams, helping discipline specialists raise


their visibility into the project and
their contributions to it up and out of
their silo of expertise, to the systems and
whole-product level.
Facilitates capture and synthesis of
expert knowledge from across the enterprise, then re-deployment of that knowledge enterprise-wide.
Prominent examples include Fords
adoption of ESTECOs SOMO to enable an enterprise MDO system, BMWs
use of Noesis Solutions Optimus as its
exclusive PIDO (process integration
and design optimization) solution, and
Rolls-Royce, whose aircraft engine development process is known for its longstanding institutionalization of design
exploration, optimization and process
integration based on SIMULIAs Isight.
Buoyed by these proof cases, and by the
technologys ever-increasing ease of implementation and use, design exploration
and optimization use should continue to
accelerate in the future. DE

Version 2.0
Now supports digital and
counter inputs
Acquire, view, and log up
to 1 million samples per
channel
Build any combination of
scalar, strip, and block
displays
Customize display size,
location, and channel/trace
colors

Bruce Jenkins is president of Ora Research


(oraresearch.com), a research and advisory
services firm focused on technology business
strategy for 21st-century engineering practice.

Export to Excel or MATLAB


Only $49 with the purchase
of an MCC hardware device

INFO Altair: Altair.com

Watch the overview video


at mccdaq.com/DAQami

Autodesk: Autodesk.com
CD-adapco: CD-adapco.com
Dassault Systmes: 3DS.com
ESTECO: ESTECO.com
Exa: Exa.com
Noesis Solutions:
NoesisSolutions.com

Red Cedar Technology:


RedCedarTech.com

solidThinking: solidThinking.com
Within Lab: WithinLab.com
For more information on this topic, visit
deskeng.com.

deskeng.com /// December 2015

Contact us
1.80 0.234.4232
2015 Measurement Computing Corporation
info@mccdaq.com

DE | Technology for Optimal Design Engineering

15

Simulation /// Hardware & Software Sponsored Report

Optimize Your
Design Process
Speed simulation-driven design by 6.9-17.7X with Altairs optimization software
and the latest hardware.

ome things are more than the sum of their parts. In


the complex world of engineering, simulation software
closely coupled with optimization capabilities makes
for a dynamic duo that radically redefines design workflows.
When simulation and optimization are powered by modern
workstations, the benefits are multiplied, allowing design engineering teams to boost innovation, lower costs and speed
time to market.

Embracing Simulation and Optimization

While many organizations have embraced simulation software, fewer have adopted optimization, and an even smaller
number have melded both disciplines into a single, integrated workflow running on the latest computing hardware.
The barriers to adoption are many. A majority of these
software tools are still oriented toward an expert audience,
making it difficult for the average engineer to tap into their
full set of capabilities. Most organizations, under pressure
to compress development cycles, cut back on the number
of iterations and delay hardware investments to save time
and short-term costs. Finally, simulation and optimization
tools often hail from different vendors, introducing layers
of complexity and incompatibilities that hinder the synergies of the two design technologies.
As a result, simulation and optimization are often put to
work later in the design cycle, and often on older computing hardware. Doing so means design teams have already
gone too far down the path to fully benefit from using the
winning combination of simulation, optimization and current hardware. This late-in-the-game approach puts engineering organizations at risk of missing out on the promise
of streamlined workflows and deep design exploration that
gives way to higher quality products that might not have otherwise been discovered.

Benchmarking Altair OptiStruct

Thats not the case with Altairs OptiStruct, a modern structural analysis solver for linear and nonlinear
problems under static and dynamic loadings. Based on

16

DE | Technology for Optimal Design Engineering

More than 17X Faster


Simulation and
Optimization

o learn more about how the


latest Dell Precision workstations and software combine
to speed your simulation and
optimization workflow, download
Optimize Your Design Process, the third in a
series of DE benchmarking reports sponsored by
Intel, Dell and independent software vendors.
Each benchmarking study pits three-year-old
workstations and simulation software against
their modern-day equivalents to see how much
time can be saved by updating both your hardware and software. In Altairs case, the new
hardware and latest software completed some
tasks more than 17X faster.
Download Optimize Your Design Process
here: deskeng.com/de/benchmark3.

finite-element and multi-body dynamics technology, and


through advanced analysis and optimization algorithms,
OptiStruct promotes the development of innovative,
lightweight and structurally efficient designs through
tightly coupled use of simulation and optimization at
each stage of the process.
Compared to conventional solvers, OptiStruct employs
intelligent memory management techniques to gain added
performance from its solution algorithms for linear, nonlinear and modal analysis problems. The tool can take advantage of the latest computer hardware advances to simulate
structures with millions of degrees of freedom (DOFs) without any model size restrictions, providing more flexibility for
extensive design studies.

December 2015 /// deskeng.com

600
500
400
300
200
100

Minutes to Completion

>17X
increase

38

Accompanying its robust solver portfolio are highly


advanced optimization algorithms, enabling OptiStruct
to solve complex problems with thousands of design
variables in a short period of time. The optimization engine lets users combine topology, topography, size and
shape optimization methods to create alternative concepts for structurally sound, but lightweight designs.
To attain the optimal performance out of OptiStruct,
our benchmarks suggest organizations should consider
investing in the latest release of the software and pairing
it with the latest workstation hardware. Our benchmark
tests show that OptiStruct version 14.0 running on a
current Dell Precision tower 7910 workstation powered
by Intel processors is up to 8X faster for some operations
compared to running its predecessor, OptiStruct 11.0,
on comparable three-year-old hardware using the same
number of cores. When OptiStruct 14.0 was given access
to all 16 of the current workstations cores, some simulations were completed more than 17X faster.
For more information, download the full Optimize Your Design Process benchmarking report for
free at deskeng.com/de/benchmark3.

674

Older Workstation,
Older Software

Newer Workstation,
Newer Software

The most impressive results were seen when running a


contact analysis of a train rail car (see below) using the newer
software and the newer workstations 16 cores vs. the older
workstations 8 cores.

Upgrades Get Results


Altair, Intel and Dell collaborated with DE to explore the impact of outdated software and hardware on present-day
simulation studies. The partners conducted a benchmark study to test vendor claims that a combination of state-ofthe-art hardware and simulation software upgrades make a big difference in the scope and performance of simulation-driven design and optimization. Below is the most impressive result of the benchmarking study, but all five of
the analyses studied showed significant reductions in run times from 6.9X to 17.7X.

Contact Analysis of a Train Rail Car

Degrees of Freedom: 5.3 Million


Contact Pairs: 10,060
Subcases: 1
Solution time:
Three-year-old workstation and three-year-old software: 674 minutes
Current workstation and three-year-old software: 284 minutes
Hardware speedup alone: 2.4X
Current workstation and current software: 38 minutes
Software speedup alone: 7.5X

Current hardware and software speedup: 17.7X


Contact analysis is used to determine the state of contact between multiple bodies. This is done by setting up
contact pairs between the nodes of one body and the elements surfaces of the other body. This nonlinear analysis is iterative and can be very slow as each contact pair affects the other. With the old workstation and old OptiStruct software, this analysis takes over 11 hours. Newer hardware speeds things up, requiring just five hours
of run time with the old version of OptiStruct. With OptiStruct 14.0 and taking advantage of the new systems 16
cores, along with a new algorithm designed for contact analysis, the analysis time drops to just 38 minutes.
deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

17

Focus on Optimal Design /// Platforms


Active Workspace provides an identical
user experience any time, anywhere, on any
modern computing device without requiring
your IT team to install and maintain devicespecific applications. Image courtesy of
Siemens PLM Software.

End-to-End Engineering
Comprehensive platforms let users design, simulate and manage a project
from one software suite, but they also raise concerns.
BY JESS LULKA

onsumers want to be able to access whatever theyd like


to at their fingertips from restaurant recommendations to the weather. While engineers are creating products that help provide an all-in-one experience to consumers,
theyre also realizing that product complexity is requiring them
to find platforms that can manage multiple workflows and different data sets to collaborate across an entire enterprise. To aid
this, companies are developing centralized ecosystems that can
integrate CAD, CAE and PLM (product lifecycle management)
capabilities within one space. Yet theres concern that trying to
connect data sets and files that arent necessarily interoperable
could either mean long implementation times or closed ecosystems.
To address these concerns, companies are creating platforms
that can give end users and industry customers the ability to
address multiple stages of the product lifecycle while also being
able to interpret each stage individually all while adding
features to improve the user experience and ease collaboration
among departments.
What matters to buyers is that the solutions they rely on
most work well together, says Monica Schnitger, president of
Schnitger Corporation, a market analysis firm that specializes
in engineering software. For some, thats CAD and CAE; for
others, its the different flavors of CAD throughout their supply
chains; for many, its managing significant amounts of data from

18

DE | Technology for Optimal Design Engineering

varying sources and controlling the work processes that create


that data. Because these needs change over time, as businesses
evolve, these platforms must be open and able to accommodate
new solutions, data types, business models and partnerships. To
make this possible, companies are charged with making engineering environments that are large enough to offer end-to-end
engineering while also providing scalability.

Dealing with Data

Despite what functions engineering teams decide to use within


an immersive platform, its imperative that data is presented in
a way that can be used throughout multiple points in the design
process and beyond to the large enterprise.
One of the main things that users and customers are looking for is a way to streamline the way that people are getting
to data, says Bill Lewis, marketing manager for Teamcenter at
Siemens PLM Software. If you consider the implications of
having an environment where its a single source that includes
multiple components, youre talking about a lot of data and a
lot of different types of people interacting with that data. This
makes it important for software companies to figure out ways
to help multiple users connect with the right context and people
for the data that they work with, he says.
At Dassault Systmes, the companys 3DEXPERIENCE
platform supports outside file formats to make data integration

December 2015 /// deskeng.com

easier. Studies have shown that engineers spend up to 40% of


their time engaged in non-value added activities (looking for information, check-in/check-out, duplicating design information,
etc.). The data-driven infrastructure of the 3DEXPERIENCE
platform enables engineers to focus on innovation rather than
administrative tasks, says Andy Kalambi, CEO of ENOVIA at
Dassault Systmes. Because the environment is centered around
design data, Kalambi notes that users can share CAD data with
each other irrespective of the original CAD authoring system,
so that information can not only be stored and accessed, but
[also] leveraged in the context of a virtual prototype.
By bringing data to the center of the platforms infrastructure, and increasing interoperability with outside applications,
software companies are easing the need for data translation and
helping multiple departments collaborate on a project. It also
gives a stronger correlation of raw data and project management capabilities letting users see the entire scale of a project.
[With 3DEXPERIENCE], project management becomes
data-driven by being linked with the product portfolio, Kalambi says. When the two processes are disconnected with
different technologies, there are multiple projects being defined and tracked, but they are not grounded in the reality of
the product data that is being created as part of the project.
Now, suppose a single technology is used to permanently as-

The average number of months


in the design cycle of DE readers
surveyed, not including the plan
or build stages, which averaged 4
and 7 months, respectively.
DEs 2015 Reader Profile

sociate the definition and development of the product portfolio


with the tracking of the projects used to govern it? The implications of portfolio decisions can be quickly assessed against
project schedule. As a result, a project manager is taking action
to resolve issues with a full understanding of the impact on the
product portfolio.

Bringing Work on the Go

In an age of social media and cloud capabilities, engineers are


seeing more technology to help them gain ubiquitous access
to their models and data. Mobility is becoming more apparent
through Web-based software access and even smartphone and
tablet applications. At this years Autodesk Accelerate event,

MARCH 7-9, 2016 | HILTON PRAGUE


LEADING ENGINEERING SIMULATION CONFERENCE
#SGC16

DISCOVER BETTER DESIGNS.


FASTER.
Join us in Prague next year for STAR GLOBAL CONFERENCE 2016

Push back the frontiers of engineering simulation and learn to tackle the most difficult problems
your industry has to offer. Join and learn from over 100 industrial simulation experts from the

EARLY BIRD 2-4-1


REGISTRATION IS
AVAILABLE FOR A
LIMITED TIME ONLY!

international engineering community at this years STAR Global Conference.


Explore the tangible benefits of simulation assisted design with a huge variety of engaging
presentations and training sessions. Plus, included with your registration is a full day of

BOOK YOUR PLACE


TODAY FOR THE BEST
TICKET PRICE!

specialized user training worth over 600!

info@cd-adapco.com
cd-adapco.com

Desktop Engineering advert oct 2015.indd 1

star-global-conference.com

deskeng.com /// December 2015

25/08/2015
DE | Technology for Optimal Design Engineering
1915:35

Focus on Optimal Design /// Platforms


Dassault Systmes
3DEXPERIENCE
environment has a datacentered infrastructure
and role-based profiles
to help users access
specific projects and
customize their own
dashboard. Image
courtesy of Dassault
Systmes.

presenters discussed what technology would enable engineers able to create a program that is simultaneously both general
to address product complexity across multiple, worldwide and specific? Corporate collaboration is one answer because
teams. Innovation and globalization are major drivers for it helps to increase interoperability among different
business and complexity. We need a new set of tools and whats platforms via integrations and plug-ins.
really enabling it is the IT, says Marc Halpern,researchvice
I dont think anybody has deployed an all-in-one kind of
president at Gartner Research, an IT research company. The solution, and there are going to be requirements to leverage
four major trends that are driving product innovation plat- what the customer already has. While we offer a broad footforms are mobility, social
print, we also have to have
networking, Big Data and
the ability to work with other
the cloud.
tools and other systems, says
To bring design and
Lewis. Having this compatsimulation into an infraibility with other software
has also led Siemens PLM
structure where engineers
Software to grow its partnercan access their data at
any time, more companies
ship programs to help provide
1. Mobility
are creating specific aptoolsets for all the use cases
Teamcenter supports. [When
plications and Web-based
2. Social Networking
creating a platform like Teamportals. Dassault Systmes
3. Big Data
offers its own 3DPlay app,
center, we ask:] What are
where engineers can mapeople already deploying and
4. The Cloud
how can you fit into those sysnipulate product data and
Gartner Research
check simulation results.
tems that they already have?
At Siemens PLM, the
says Lewis.
companys Active WorkLewis sentiment isnt unspace enables PLM management from a Web-browser. By common. Partnerships to help create a more encompassing
offering engineering software inmediums that are similar design environment are appearing elsewhere in the industry.
towhat designers use as consumers, it can remove some of For example, Autodesk, National Instruments and the Unithe technical overhead.With Active Workspace, weretry- versity of California, Berkeley have launched a partnership to
ing to take lessons on how users are interacting and working help connect and streamline the tool supply chain. The goal
with the online world in their day-to-day life [and apply that of this collaboration, is totake the output of Autodesk Invento PLM], says Lewis.
tor, put it together with Modelica [an object-oriented system
modeling language], and feed it into the simulation and conFilling in the Gaps with Partnership
trol design module in [NIs] LabVIEW, according to Dave
With these environments offering multiple roles and
Wilson, academic marketing director at National Instruments.
personas for engineers to access data, how are companies
(For more, see deskeng.com/virtual_desktop/?p=10948).

The 4 Trends Driving


Product Platforms

20

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

Cause for Concern?

While a more complete design environment can offer a central access point for multiple project stages, companies also
need to address concerns of scalability, interoperability and
long implementation times. As a solution, environments will
often have a certain amount of customization available to addon to the main infrastructure.
The modular architecture of the 3DEXPERIENCE platform provides the flexibility to enjoy the collaborative benefits of the base solution and add role-based apps, as needed.
The available apps span design, simulation, manufacturing
and more, and are available tailored for specific industry challenges, says Kalambi. He also notes that to help more industries, the company has expanded its base beyond manufacturing to newer sectors such as life sciences and packaged goods.
Lewis says that Teamcenter has developed Rapid Start, a
preconfigured solution that includes some common industry
best practices and features for PLM. By providing an out-ofthe-box foundation, customers can start using the softwares
capabilities more quickly and then decide if it needs to be expanded or customized.
However, even with larger end-to-end engineering environments, its rare that a company decides on a complete
switch to a new platform. Its usually a more organic process,

where a division or product line selects a new tool because it


has capabilities that the legacy solution doesnt provide, and
proves out that this approach works only then is the new
platform rolled out on a wider basis. Today, the platforms
more often need to mold to the enterprises needs. Todays
incremental approach is faster, less disruptive and can build
success a bit at a time, Schnitger says.
Despite the idea of the design platform becoming more
apparent in industry, engineering teams still need to have software that is scalable and accessible. By creating platforms that
offer customization beyond a main infrastructure, mobile and
Web portals, and the ability to integrate outside niche software, companies are setting a new standard for collaborative
engineering.DE

Jess Lulka is associate editor of DE. Send e-mail about this article
to DE-Editors@deskeng.com.

INFO Autodesk: Autodesk.com

Dassault Systmes: 3ds.com


Siemens PLM Software: Siemens.com/plm
Schnitger Corporation: SchnitgerCorp.com
For more information on this topic, visit deskeng.com.

W O R K S TAT I O N

WT72
LATEST 6TH GEN INTEL CORE i7 & XEON PROCESSOR
PROFESSIONAL NVIDIA QUADRO M5000M GRAPHICS SOLUTION
DDR4 MEMORY UPTO 64GB W/ ECC SUPPORT
PCI-E GEN 3 X 4 SSD STORAGE SOLUTION
ISV CERTIFIED FOR AUTODESK MAYA & 3DS MAX

MEET US AT: AUTODESK UNIVERSITY 2015 BOOTH #1149 | DECEMBER 1-3, 2015 | LAS VEGAS | NV
MSI MOBILE WORKSTATIONS
DESKTOP PERFORMANCE IN A PORTABLE PACKAGE
deskeng.com /// December 2015

FIND OUT MORE:


US.MSI.COM/PRODUCT/WORKSTATON
DE | Technology for Optimal Design Engineering

21

Rendering /// Sponsored by NVIDIA

Fast, Predictive Rendering


Unambiguous and fast iteration transforms design workflows.

esign is the key differentiator among


products in todays economy, but
predictability and iterative speed are
key differentiators in the economics of design. At its heart, design engineering is the
process of iteration: An idea is visualized,
critiqued and refined, until it is ultimately
delivered. More iterations mean more
chances to try new ideas, to catch mistakes,
to polish concepts into ever better designs.
Its not enough, however, to have a beautiful
design. Speed to market and cost of production are both essential in the creation of a
competitive, profitable product. While its
important to do enough design iterations,
the changes need to happen quickly and with By incorporating physically based rendering into the upfront design
the confidence that the final product will process, design engineers can iterate in real time and see how modifying
a parts shape or material will affect the look of the final product.
emerge as the designer intended.

Interaction via Physically Based Rendering

Rendering has long been an important tool for visualizing


3D designs. Real-time display renderers, such as OpenGL,
lend themselves well to rapid iteration. However, such
rendering can only approximate the appearance of materials and objects. It is often useful for working with the mechanical components of a shape, but it cannot accurately
predict the appearance of a finished product, meaning the
designer can only make educated guesses. Various forms
of ray tracing, and other CPU-based rendering methods
that simulate light more realistically than OpenGL have
been available to designers for years, but these have been
difficult to use and too slow to fit well into rapid iterative
design. As a result, many designers have simply learned to

do without realistic rendering, or they have saved it for


special occasions.
Interactive, predictive, physically based rendering (PBR)
is poised to change the way such designers work. It combines easy-to-use physically based lighting, verifiable realistic materials and reliably accurate photorealistic results,
with the computational performance of graphics processing
units (GPUs). Not only can a designer see how the product
will really look, he can see it in his applications interactive
viewport, while he designs it. Just as hardware-accelerated
OpenGL became the standard mode for working interactively in 3D, GPU acceleration turns physically based rendering into an interactive design mode that will become an
essential part of iterative design workflows.

Making the Case for Predictive Rendering

his new paper produced by DE on behalf of NVIDIA makes the case for using physically based rendering early and often in the design process to transform your iterative
design workflow. Thanks to the power of GPUs, modern rendering software is capable
of producing realistic visuals in real time, allowing you to immediately see the results of
design changes without costly prototyping and manufacturing.
Making the Case for Predictive Rendering explains the key concepts and benefits
of predictive design, and includes real-world examples to show how Harley-Davidson and
Renault are using it to get better products to market faster. Download the paper for free at
deskeng.com/de/predictive.

22

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

4 Reasons for
Predictive Rendering

predictive design approach that leverages


realistic, iterative rendering can accelerate
the design workflow, help designers identify
flaws earlier in the process, increase creativity, save
costs and provide a platform for better decision
making and collaboration with non-engineers during
the product development process. GPU-accelerated,
physically based rendering (PBR) ultimately improves
the end product.
To convince your team to incorporate predictive
design into your overall product development workflow, focus on these four points:
Easier, faster rendering allows you to make
better use of your time, completing your work
faster. With Iray-enabled PBR, designers can
explore more concepts in less time, and have confidence that what they see in the photorealistic rendering accurately reflects what the design will look like
when it is built.

SWITCHING TO IRAY RAY TRACING WAS


LIKE A DREAM WE CAN GO SO QUICKLY
FROM IDEA TO RENDER. THERES
NO PRE-PROCESSING REQUIREMENT.
MATERIAL AND GEOMETRY CHANGES
ARE MADE EXTREMELY EASY TO
HANDLE INTERACTIVELY AND IN NEAR
REAL-TIME.
RENAULT DESIGN DIGITAL VISULAZATIONS GUILLAUME SHAN

Potentially catastrophic design flaws can be


identified earlier in the process through visualization. This saves expensive re-work down
the road and improves client satisfaction. Having
access to a lifelike representation earlier in the
design process ultimately results in better products,
because engineers can make design decisions faster and more effectively.

Managers and clients can clearly see the


impact of a design change, or better understand the intent of a design idea in real-time.
This improves collaboration, saves time and further
speeds the development cycle.

By enabling the design engineering team to


create realistic digital prototypes on demand,
you can save the cost of creating physical
models and prototypes. Reducing or eliminating the
number of physical models/prototypes required can
result in significant savings.

Learn more by downloading Making the case for


Predictive Rendering via deskeng.com/de/predictive

IT USED TO TAKE FOUR PEOPLE ON OUR


TEAM A FEW MONTHS TO DEVELOP A
NEW BIKE DESIGN. NOW, TWO PEOPLE
CAN DESIGN A FULL MOTORCYCLE IN
TWO WEEKS.
HARLEY-DAVIDSON SENIOR SURFACE DESIGNER
MATTHEW GUELLER

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

23

Focus on Optimal Design /// Digital Twins

Avatars Land a Role


In Product Design
The concept of a digital twin is gaining traction as companies look
at connecting the physical product to its virtual counterpart.
BY BETH STACKPOLE

iven the ever-increasing complexity of todays multidomain products, the practice of digital prototyping is
evolving with the digital twin a concept that carries
the traditional 3D representation of a product into the new reality of a converged physical and virtual world.
While definitions vary, the digital twin is increasingly being
used as a way to describe a means of connecting information
about the physical product and its behavior in the real world
with the 3D digital representation so commonly employed by
engineering and other areas of the business. The requirement for
viewing, interacting and getting information about the product
in a blended virtual and digital world is in part being driven by
the Internet of Things (IoT) and the rise of connected products.
Product complexity is driving a need to bring multiple
people together more efficiently to collaborate and that is accelerating the need to create convergence between the real and
virtual worlds, says Eliane Fourgeau, CATIA Systems senior
director of Sales at Dassault Systmes. Its critical because you
need to make sure the product youre putting on the market is
the right product and is delivering the right services.
Thats one companys view of why a digital twin is important.
Dassaults primary competitors in the CAD space PTC, Siemens PLM Software and Autodesk are also bullish on the
concept and its potential benefits, but they all have different
ideas of what constitutes a digital twin and alternative plans for
where it fits best in the scheme of a products lifecycle. All are in
agreement, however, that a digital twin can deliver efficiencies
to the design and production processes, improve product quality and innovation, and foster better serviceability of products,
ultimately benefitting customers.
For Dassault, the concept of a digital twin (or a virtual twin,
as the company prefers to call it) is an extension of its systems
engineering strategy, enabling design teams to conceive and architect a cross-disciplinary product that combines mechanical,
electrical, electronic, hydraulic and control capabilities, among
other domain properties. As part of its 3DEXPERIENCE
strategy, which is an environment for engineering a system
or a product in the context of its whole experience, the con-

24

DE | Technology for Optimal Design Engineering

PTCs vision of a digital twin involves a one-to-one


representation of an individual product. Image courtesy of PTC.
cept of virtual twin will enable design teams to experience a
product before it exists. In this way, engineering teams see not
just static mockups of a product or system (the traditional 3D
digital mockup driven by CAD), but rather provide insights into
physical behaviors like stress and vibration as well as behaviors
associated with the software and control systems, Fourgeau explains. In a sense, think of it as creating an avatar that behaves
as something would in real life, she says.
Essential to Dassaults strategy are model-based design capabilities for modeling, simulating and validating complex engineering systems. As part of its systems engineering portfolio, the
3DEXPERIENCE platform uses the Modelica language and
Functional Mockup Interface (FMI) standard so multi-physical
systems can be modeled and easily composed, promoting reuse
and cross-domain exchange while supporting an open ecosystem, Fourgeau says.
Creating and leveraging this virtual twin at the beginning
of the process not later on in the detailed design stage is
one thing Dassault says sets its strategy apart from competitors.
Take the example of an energy efficient building you can
wait until you build it, put sensors in, and have an IoT system

December 2015 /// deskeng.com

tell you if its efficient or not, or you can create a


virtual representation of that building and experiment, putting double pane glass here or changing
the exposure of the building with regards to sun,
Fourgeau says. In that way, you continue to play
what-if scenarios until you are satisfied and then
start the detailed development of the building.
Siemens PLM Software sees the concept of the digital twin as
the intersection of four different worlds coming together: Product design, manufacturing planning, factory design and the real
world with an emphasis on production. The digital twin does
something very unique by merging the virtual and real worlds
of production, says Aaron Frankel, senior director of product
marketing for Siemens PLM Software. Now you can take the
as-designed model and all the information you are collecting
from the production environment about performance and quality, overlay them on a digital model, and compare the as-designed
and as-built worlds to see if there is a difference, he says.
This view advances the concept of digital prototyping by
taking into account all that can happen with production processes, full proofing a product design by eliminating the possibility of failure, according to Zvi Feuer, Siemens PLMs vice
president of Manufacturing Engineering Software. The digital
twin is the avatar of the product process and the factory all to-

Using Autodesks SeeControl technology, real-time sensor


data from a robotic arm is collected, analyzed and displayed
in an easy-to-digest format. Image courtesy of Autodesk.
gether, he says. If you can take failure off the table, companies
will be willing to be bolder and take bigger risks.
The underpinning of Siemens digital twin concept is the
Teamcenter data management and collaboration platform along
with various other components, some from its simulation and
factory optimization tools and others from its Manufacturing
Execution System (MES) and factory automation suite.
Autodesks digital twin vision spans both the factory and
product, making use of augmented reality technologies borrowed from its media and entertainment software line as well as
capabilities from SeeControl, an IoT cloud services platform provider it acquired in August. SeeControl is the underpinning of
our digital twin, says Diego Tamburini, manufacturing industry

PERFORM
ELECTROMAGNETIC
FIELD ANALYSIS
IN SOLIDWORKS
Save time.
Design more.
MagNet for SolidWorks is the foremost 3D electromagnetic
celd simulator embedded in the industry leading CAD software.
A combination beyond compare: just one design environment for drawing the
model and analyzing the performance of any EM device such as power transformers,
sensors, MRI, actuators, solenoids and much more.
Perform simulations and quickly make geometric changes to see their impact on your design without
worrying about exporting model data and dealing with compatibility issues.
SolidWorks is a registered trademark of Dassault Systemes SolidWorks Corporation

YOUR FASTEST
SOLUTION TO A
BETTER DESIGN
ELECTROMAGNETIC SPECIALISTS SINCE 1978

deskeng.com /// December 2015

866 416-4400
Infolytica.com
info@infolytica.com
DE | Technology for Optimal Design Engineering

25

Focus on Optimal Design /// Digital Twins

strategist at Autodesk. It allows you to quickly connect to a sensored device and get data, which can be overlaid on a 3D model.
Viewing that data overlaid onto a real physical product using
augmented reality technology is where the rubber meets the
road, Tamburini says. Theres an obvious advantage to looking
at data at the source for example, looking at temperature
or stress values in the exact location of the product, he says.
Thats very intuitive and you dont have to do any mapping in
your head. If youre looking at a 3D model, it takes too much

20%

The profitability and


productivity gains GE
hopes to achieve via its
digital twin wind farm concept .
GE Power

black magic to get the sensor data displayed there.


Augmented reality will be part PTCs digital twin vision in
light of its acquisition of the Vuforia technology (see page 7).
For now, however, the company is talking about the concept
in the context of product development, but more vociferously
in the area of field service and operations, according to Mike
Campbell, PTCs executive vice president, Digital Twin.
Unlike the traditional CAD model used in virtual prototyping, which is a general representation of a multitude of products,
Campbell says PTC sees the digital twin as a one-to-one representation of a unique physical product already out there in the
real world. A digital twin associated with a specific product is
the key idea here, he says. Its this one-to-one mapping that
makes it different than CAD and different from what some of
our competitors are doing.
A 3D CAD model is highly valued during the design process,
but loses utility once the product leaves the manufacturing floor.
In contrast, a digital twin of a smart, connected product can provide insight into how the product is behaving in the field, helping
to steer product design and provide intelligence for successful
service calls, Campbell says. People design products all the time
against idealized requirements they over- or under-engineer

26

DE | Technology for Optimal Design Engineering

Using the Tecnomatix process planning and simulation


tools, Comau is able to create a digital twin to validate
production lines. Image Courtesy of Siemens.
things or products and miss the mark entirely because they didnt
understand real-world use cases, he says. The connectivity and
digital twin provide an opportunity to understand how a product
is used and leverage that insight to make the product better.
PTC is planning a January launch of its official digital twin
strategy. While Campbell declined to discuss the specifics, he
said that the company is assembling a portfolio of technologies, which will include augmented reality capabilities, tools for
managing the one-to-one relationship, mechanisms to collect
relevant data from sensors, and a way to integrate information
from other enterprise systems.
Sysmex, a manufacturer of clinical diagnostic equipment,
sees potential for the digital twin for both field service and product design applications. On the service front, field technicians
might receive a digital picture flashing warnings to flag conditions that exist with a particular medical instrument rather than
trying to discern something from data in a table view.
For Sysmex product designers, the digital twin will provide
essential feedback on non-tangible information that can help
drive future development. By having a digital twin, field service
technicians can provide detailed information about what exactly
they adjusted, cleaned or lubricated rather than just providing
general guidance, says Steve Postma, enterprise architect at
Sysmex. Now engineering and development teams have a clear
serviceability picture of whats happening with the product and
can leverage that in future designs. DE

Beth Stackpole is a contributing editor to DE. You can reach her


at beth@deskeng.com.
INFO Autodesk: Autodesk.com

Dassault Systmes: 3Ds.com


Siemens PLM Software: Siemens.com/plm
PTC: PTC.com
Sysmex: Sysmex.com
For more information on this topic, visit deskeng.com.

December 2015 /// deskeng.com

TABLE OF
CONTENTS

Optimal Design Leaders


BOXX Technologies

Optimize Your Performance Page 28

CD-adapco

Discover Better Designs, Faster Page 29

COMSOL

Spreading Virtual Prototyping and Design


Optimization Through Simulation Apps Page 30

Dassault Systmes SIMULIA

From Solve to Innovate Page 31

ESTECO

Design Products as a Whole Page 32

Rave Computer

Rave Computer Resolves New Design


Engineering Challenges Page 33

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

27

Special Sponsored Section

Optimal Design Leader /// BOXX Technologies, Inc.

Optimize Your Performance


Workstations customized for engineers improve productivity.
BY SHOAIB MOHAMMAD, Vice President of Marketing and Business Development

or todays engineers, the computer workstation is their most


important tool, yet it also presents one of their greatest challenges.
The proper solution optimizes productivity, but this is where commodity PC makers, with their one size
fits all approach, usually fail to deliver. They dont understand professional applications and the specific
configurations needed for workflow
optimization, often resulting in misinformation. To further complicate
matters, engineers face an increasingly competitive marketplace. If
you rely on inaccurate information
from your hardware provider, and as
a result, are saddled with an expensive system that doesnt maximize
your productivity, youre behind the
curveand your competition.
Knowledge is power, and as a solution provider, BOXX customizes systems to optimize workflows because
our expert performance specialists, engineers, and legendary technical support not only know everything about
our Autodesk and Dassault Systmes
certified hardware; they also have an
intimate understanding of these applications and workflows. And because
BOXX designs and manufactures in the
U.S., were more agile, quickly adopting leading technologies in response to
customer needs. Our unique offerings,
with features like safe overclocking, liquid cooling, and multiple GPUs backed

by a full, three-year warranty, have all


become BOXX trademarksjust like
customer satisfaction.
Enfinity Engineerings Richard
Howard, discussing simultaneous jobs,
each with a critical deadline, says (without his BOXX), Theres no way I could
have done all the crunching, the reloads,
the opening and closing, popping back
and forth, and still make my deadline.
Two-time SOLIDWORKS International Design Competition winner Bill
Gould credits his BOXX workstation

for a productivity increase of at least


30 percent. I dont have to wait for
anything in SOLIDWORKS, he says.
More importantly, it has opened up
new possibilities because what I can do
now, I can do faster.
Working faster and more efficiently is the key to any engineering
teams success. BOXX understands
this and that is why we are uniquely
positioned to help you meet your engineering challenges and maximize
your productivity.

About BOXX Technologies, Inc.


OXX is the leading innovator of high-performance workstations
and rendering systems for engineering, product design,
architectural visualization, visual effects, animation, and more.
Combining record-setting performance, speed, and reliability with
unparalleled industry knowledge, BOXX is the trusted choice for
creative professionals worldwide. Hear what our satisfied customers
have to say: www.boxxtech.com/whyboxx

Contact Information:

10435 Burnet Rd #120, Austin, TX 78758


(512) 835-0400
www.boxxtech.com

28

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

Special Sponsored Section

CD-adapco

/// Optimal Design Leader

Discover Better Designs, Faster


Multidisciplinary Design eXploration speeds product innovation.
DAVID L. VAUGHN, Global Vice President, Marketing

o design better products, engineers need to be able to


quickly predict the outcome
of design changes on the real-world
performance of the product. To be
most effective, these predictions
should be delivered early and often,
providing a constant stream of data
that influences the product from the
very earliest point in the design process. In short, the ongoing challenge
in engineering is to discover better
designs, faster.

Engineering Across Disciplines

Multidisciplinary engineering simulation provides the most reliable flow of


information into the design process,
while providing comprehensive predictions that are usually more accurate and
always less expensive than the experimental testing. Deployed effectively,
simulation can be used to improve a
product or design by providing a stream
of engineering data to drive the design
through multiple design iterations. In
addition, engineering simulation opens

the door to intelligent


and automated design
exploration and optimization. Ultimately, the
implementation of this
Multidisciplinary Design eXploration (MDX)
process results in higher
quality and more robust
products that exceed
customer expectations.

Innovative Solutions Backed


by Experts

CD-adapco is an engineering simulation company with a unique vision for MDX. Our flagship product, STAR-CCM+, along with our
other multidisciplinary engineering
simulation technologies, predict the
real-world performance of products
accurately and robustly. They can be
used to explore and evaluate product
performance throughout a range of design configurations and operating scenarios. They provide timely solutions
by employing efficient algorithms and

About CD-adapco

D-adapco is an engineering simulation company with a unique


vision for Multidisciplinary Design eXploration (MDX). Our purpose
is to facilitate innovation and to lower product development costs
through the application of multidisciplinary engineering simulation and
design space exploration. Put simply, our mission is to allow our customers
to discover better designs, faster.

automated and repeatable CFD and


CAE processes that are optimized for
modern parallel and cloud computing.
Our solutions are backed by a staff
of engineering simulation experts
located around the globe. The company provides unprecedented support
through our designated support engineer format, along with the Steve portal that provides online resources 24/7.
CD-adapco is synonymous with innovation. Indeed, we pioneered much
of the software technology that makes
engineering simulation possible, and
we also led the market in offering innovative licensing options to make MDX
affordable. The Power Session license
revolutionized the industry by offering unlimited parallel computing access for a fixed price. We then brought
engineering simulation to the cloud
with our Power-on-Demand licensing,
which gives users a pay-as-you-go option. Now, Power Tokens complement
the MDX vision by enabling affordable
licensing for design exploration.

Contact Information:

60 Broadhollow Road, Melville, NY 11747


Email: info@cd-adapco.com
www.cd-adapco.com
deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

29

Special Sponsored Section

Optimal Design Leader /// COMSOL, Inc.

Spreading Virtual Prototyping and Design


Optimization Through Simulation Apps
Simulation specialists can extend versatile multiphysics simulation
design capabilities to an entire organization via apps.
BY VALERIO MARRA, Technical Marketing Manager

odern product design tools are


indispensable to the engineer,
enabling virtual testing of your
first idea to the verification and optimization of the designs and processes necessary to manufacture high-quality products. The advantages of a simulation-led
workflow extend throughout an organization or company by allowing your
design teams to innovate with reduced
risk, cutting the cost and time associated
with physical prototyping, while meeting
time-to-market goals.

Eliminate the Workflow Bottleneck

Your organization or design engineering


team could face significant challenges in
implementing such a workflow, despite
their numerous advantages, because
highly trained specialists are required.
Additionally, a small group of experts
often have to serve an entire organization
while covering a diverse range of simulation needs. A bottleneck results, limiting
the pace of the product design cycle and
innovation, which in turn affects competitiveness and future revenue.
The latest version of COMSOL Multiphysics software and its Application
Builder provide you with the tools needed
to turn detailed physics and mathematical
models into easy-to-use simulation applications for use by everyone in your organization and beyond. Thus, the workflow
bottleneck is bypassed.

committed to providing engineers with


easy-to-use, affordable simulation and
application design tools as well as access
to highly skilled support engineers. With
COMSOL Multiphysics, engineers from
a diverse range of technical areas can
solve systems of equations representing
coupled physics effects as they would
occur in nature; hence you can base your
design decisions on highly accurate data.
Running your design optimization
based on this real-world model is a great
competitive advantage. COMSOL provides add-on products such as the Optimization Module as well as products
for interfacing with CAD software to
enable topology optimization, inverse
problems, and time-dependent optimization analyses.
A simulation application can be developed for a specific design optimization
task, and presents only those parameters,
results, and reports that may be of interest to the user. There is no learning curve
to run simulation apps, and users wont

Design Optimization
with Simulation Apps

To continue addressing your most critical workflow challenges, COMSOL is

30

DE | Technology for Optimal Design Engineering

The thermal properties of a finned


pipe are derived from a conjugate heat
transfer simulation app.
require previous experience in using
modeling and simulation software.
COMSOL specifically developed
COMSOL Server, a software that
makes it possible to run apps in a readily available COMSOL Client for Windows or in any major web browser. With
its generous license, costs for large-scale
deployment are minimized, and apps can
run on local hardware or on the cloud for
worldwide use. With Application Builder
and COMSOL Server, you can bring
easy-to-use simulation apps to everyone.

About COMSOL, Inc.

OMSOL is a global provider of modeling and simulation software.


Its COMSOL Multiphysics and COMSOL Server products offer an
integrated software environment for creating physics-based models
and simulation apps that can be readily deployed and accessed by users in
design teams, manufacturing departments, and test laboratories, as well as
by customers throughout the world.

Contact Information:

1 New England Executive Park, Burlington, MA 01803


(781) 273-3322
Email: info@comsol.com
www.comsol.com

December 2015 /// deskeng.com

Special Sponsored Section

Dassault Systmes

/// Optimal Design Leader

From Solve to Innovate


Capture the Power of Simulation to Optimize
Product and Business Performance
BY SUMANTH KUMAR, VP, SIMULIA Portfolio Management

ith shorter timelines, reduced


budgets, more stringent regulations and greater technical
complexity product developers are relying more heavily on a range of simulation
technologies.
Dassault Systmes has responded
to this industry demand by making technical breakthroughs in solver
performance, accuracy, scalability,
material modeling, assembly modeling, contact analysis, fracture and fatigue, multiphysics co-simulation and
efficient optimization technologies.
These technologies are all easily accessible through Extended Packaging for
Abaqus, Tosca, Isight and fe-safe, which
provides efficiency, flexibility and scalability to access the technology you
need when you need it.

A Holistic Approach

However, robust technology on its


own is no longer sufficient. The issue
facing most companies is not only
how to use more simulation solver

technology, but how to integrate the


technologies and leverage the benefits of simulation and optimization to
power innovation. Companies need
to bring simulation out from the back
corner of the engineering department
and onto center stage in their business processes.
Dassault Systmes is leading the
way by providing integrated simulation technologies as well as a platform
for collaboration and management of
simulation intellectual property. The
3DEXPERIENCE platform transforms the way products are designed,
produced and supported. With our
platform, industry-focused solutions,
and expansive partner ecosystem we
are empowering companies to make the
transition from solve to innovate.
The platform enables simulation
to be an integral part of the crossdisciplinary workflows tailored to
each specific industry. Entire development processes with requirements, design variants, simulation

About Dassault Systmes

assault Systmes, the 3DEXPERIENCE Company, provides


businesses and people with virtual universes to imagine
sustainable innovations. Its world-leading solutions
transform the way products are designed, produced, and supported.
Dassault Systmescollaborative solutions foster social innovation,
expanding possibilities for the virtual world to improve the real world.
The group brings value to over 190,000 customers of all sizes, in all
industries, in more than 140 countries.

models, and results are maintained


as part of the same single source of
truth for product and experiencerelated data. Any changes are automatically reflected in the system of
record, which makes it possible for
everyone to be fully aware of their
colleagues contribution at each
stage of development.
The integration of realistic simulation, process capture, automation,
optimization and analytics within the
platform enables companies to democratize simulation by sharing best
practices. It also accelerates exploration of multiple options and supports
collaboration across multidisciplinary
teams to zero in on alternatives that
may have never been considered with
traditional methods.
The 3DEXPERIENCE platform,
combined with the breadth of SIMULIA
applications, enables simulation to be essential for achieving optimal processes
and designs. This helps companies deliver high-performing, innovative products while reducing cost, time and risk.

Contact Information:

175 Wyman St, Waltham, MA, 02451


(781) 810-3000
www.3ds.com

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

31

Special Sponsored Section

Optimal Design Leader /// ESTECO

Design Products as a Whole


Optimize engineering collaboration with the enterprise.
BY CARLO POLONI, President of ESTECO

he dynamic nature of modern markets has radically changed the way


manufacturers approach product
design, and so far technology has risen
to the occasion by providing tools to improve and innovate products. The challenge today and for the future is enabling
collaboration, where sharing knowledge
and decision making go hand-in-hand
with technology to speed up design processes and engineer better products.
ESTECO meets this challenge by
providing tools that manage the interaction between different engineering disciplines, enabling companies to design
products as a whole rather than as a set
of individual components. Our software
automates the design process and gives
our customers advanced data mining capabilities: designers can use an array of
leading-edge post processing tools to extract relevant information and transform
it into insightful and actionable analyses.

Pioneering Technology Recognized

Our strategy at ESTECO has always been


to be better than everyone else to create
something new and different from what is
currently available thats why we are considered a pioneer in our field. What distinguishes ESTECO is our long history in,
and experience with, traditional technology through the engineering of products
and our ability to anticipate the future of
IT technology. Its no coincidence that

Gartner, the IT consulting company,


singled us out in their 2015 Product Design and Life Cycle Management Cool
Vendors Report when we moved from a
very technical desktop solution to an enterprise solution where interaction with
IT is the prime focus. In the beginning,
our customers were individuals designing
a single component on their PC. Nowadays, we are moving toward a scenario
where our technology is used throughout
the company and accessible to managers
and different experts within the company.
This means that the judges of our software
are no longer specialists working at their

desks, but the very companies themselves.


Convincing companies of our technical
prowess is no longer enough, we also need
to prove we are a stable, reliable and innovative company, and Gartners endorsement goes a long way toward doing that.
Its not obvious to those who dont know
us, but wherever I look, wherever I go, I
see things designed using our technology.
Now, the world gets to know what we do,
and I find that incredibly exciting. Being a
Gartner Cool Vendor will make our lives a
bit easier by raising awareness of ESTECO
to companies that may not be aware of us
and what our technology can do.

ESTECO Insights

s a pioneer in numerical optimization, ESTECO provides innovative


technology that enables engineers to make the most of their
expertise while giving free rein to their creativity. As design
complexity grows and demands for time and cost-effective tools rise,
so does the need for technologies that effectively manage complexity
simply and rapidly. For over 15 years, ESTECO has been at the forefront
of optimization technology and continues to provide industry with
best-in-class solutions that makes life easier for engineers.

Contact Information:

ESTECO North America 1221 Brickell Ave. Suite 900 Miami, FL 33131 U.S.A.
ESTECO SpA AREA Science Park, Padriciano 99, 34149 TRIESTE (ITALY)
www.esteco.com

32

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

Special Sponsored Section

Rave Computer

/// Optimal Design Leader

Rave Computer Resolves New


Design Engineering Challenges
High-performance computing power for digital workflows.
BY MIKE LAJOICE, Commercial Business Unit Manager

esign engineers are up


against new challenges, and
Rave Computer is ready to
help. Modeling a design in its reallife behavior is now a common expectation. Physical characteristics
and photorealistic results give the
customer an interactive real-world
result. This evolution has been expedited by advancements in software
vendors products that provide tools
to quickly move from design concept
to product manufacturing with fewer
people and greater digital quality.
Digital design with realistic rendering reduces the need for multiple
physical prototypes, saving both time
and money.

Optimized Hardware

Advances in engineering design and


simulation software have put a strain
on computer hardware, IT infrastructure and IT overhead. At Rave
Computer, we work directly with the

software vendors to provide computer hardware that is optimized for


their software requirements.
Rave Computer brings high-performance computing power to your
desktop with the Beast product line.
Putting power at the fingertips of
engineers improves their productivity, reduces traffic to offsite clusters,
and minimizes IT overhead as they
support simpler desktop workstations instead of complicated computers in server rooms. When the addition of cluster computing is needed,
Rave Computer complements its
high-performance workstations by
delivering condensed, optimized,
high-performance racked systems
that can be portable and installed in
engineering rooms or racked into existing server rooms.
Rave Computer has been delivering high-performance, whisper quiet,
semi-rugged computer solutions to
the Defense and Commercial indus-

About Rave Computer

tries since 1988. Rave Solution Architects are onsite at engineering and
design facilities, working through
technology issues to ensure that we
are always developing and delivering current and advanced technologies to the industry. Sales, Product
Develop, Warehouse and Product
Build are all housed in the same
35,000 sq. ft. facility, allowing for efficient transfer of new product ideas
through production to the customer.

ounded in 1988, Rave Computer is a technology consultant and


computer manufacturer providing commercial-off-the-shelf and
custom engineered solutions optimized for specific customer
requirements. Driven by a focus on long-term relationships with
customers, Rave continues to grow in recognition throughout the
Defense, Simulation and Training, Commercial, High-Performance
Computing and OEM/Custom Hardware markets.

Contact Information:

7171 Sterling Ponds Drive, Sterling Heights, MI 48312


(800) 966-7283
www.rave.com
deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

33

Focus on Optimal Design /// Industrial IoT

Getting on Board with the


Industrial Internet of Things
Although the Industrial
Internet of Things, or IIoT,
is still in its infancy, standards and best practices
for security and interoperability are already
emerging.
BY MICHAEL BELFIORE

he 10-ton cranes that moved


around pieces of stamped and
welded metal to be sent to an
auto plant from Kalida Manufacturing in
Ohio were burning through parts. Motors, switches and brakes had to be serviced or replaced every couple of months
keeping maintenance costs high and
plant managers unable to figure out
why. Adding to the mystery: Brand new
cranes supplied by Konecranes also went
through parts at an alarming rate.
But those new cranes had a feature
the older models lacked: they were
connected to the Industrial Internet of
Things (IIoT), which meant that they
continually reported operational data to
a central database.
All it took was a look at that data to
pinpoint the problem: Each crane was
logging more than 20,000 motor starts
and stops every single week. This is basically 167 times an hour, explains Jim
Skowron, regional vice president of sales
at Konecranes. Thats an incredible
amount of stress on that hoist motor.
Using the data, plant managers were finally able to trace the maintenance problem to simple operator error.
Previous generation cranes ran on just
one speed; to slow one down as it was rais-

34

Konecranes has been involved in the lift industry for more than 80 years.
It now has almost 12,000 employees in 47 countries. Images courtesy of
Konecranes.

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

ing or lowering a part required the kind of


rapid starts starts and stops the operators
were doing, even though both the new
Konecranes machines, and their immediate predecessors in fact, had two speeds.
Solving the maintenance problem was
a simple matter of training the operators at the plant to press motor switches
halfway in for a lower speed, and all the
way in for a faster one. Practically overnight, the motor starts and stops were
reduced by more than half. Maintenance
became more of a biannual affair than a
bimonthly one. And with the simple application of relatively inexpensive training sessions, maintenance costs were cut
more than in half.
Konecranes IIoT solution, called
TRUCONNECT, provides just one
example of how the IIoT is transforming industry by providing never-beforeachievable insight into industrial processes. Everything from manufacturing
and transportation to energy production

47%

of DE readers surveyed were


already involved or expected
to be involved in developing
Internet of Things products.
January 2015 DE Reader Survey

and agriculture will benefit from the


IIoT revolution now underway, according to a report released by the World
Economic Forum in January 2015 titled
Industrial Internet of Things: Unleashing the Potential of Connected Products
and Services.
But significant risks also loom ahead,
as increasing numbers of machines and
processes going online expose themselves
to the wider Internet, warns the report.
Along with security, Richard Soley,
Executive Director of the Industrial Internet Consortium (IIC), also cites interoperability as a major challenge that
need to be addressed by engineers and

managers building IIoT systems in order


to realize the full potential of the Industrial Internet of Things.

Interoperability

Most technologists focus on the wrong


problem, Soley says of the effort to address the challenge of interoperability
that is, getting machines and other
devices of different types to share data.
They focus on the middleware: How do
I get the bits and bytes moved around,
says Soley. Thats an easy problem, and
its in fact been solved a long time ago.
The harder challenge to overcome, says
Soley, is that the bits and bytes are all

Fast
Fast
Fast quotes.
Fast
Fast
Fast
Fast parts.
ONLINE MOLD QUOTES
Use our online mold quoting tool to get a fast quote for
your next plastic injection molding project. Visit ICOMold.com
and get started.
Have a quote in your hands in one business day!

ICOMold.com
deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

35

Focus on Optimal Design /// Industrial IoT

Konecranes TRUCONNECT suite of remote service products that connect


data, machines and people via the Industrial Internet of Things.
coming from devices of different types
that use different protocols to communicate. In other words, they speak different
languages.
It might be tempting to suggest the
creation of a common protocol that all
future devices could share, says Soley,
but he cautions that this would only add
to the problem. He says such a solution
would simply add yet another standard

42%

AT&T, Cisco, GE, IBM and Intel


founded the IIC in March 2014 to do
just that. Each member company contributes expertise, personnel, and other
resources in the service of developing best practices and standards for the
emerging IIoT through the creation of
testbeds. Even more than that, says Soley,
the IIC is charged with developing entire
new business models that will make even

of Konecranes total sales


comes from providing services,
much of it driven by data from
its connected machinery.

Juha Pankakoski, Konecranes chief digital officer,


at the 2015 Siemens PLM Software Industry
Analyst Conference

to the protocol soup as manufacturers


continue to support old protocols and
also continue to develop new ones to
take advantage of emerging capabilities.
Instead, says Soley, the best solutions to
the interoperability problem will be systems that can act as translators between
devices using different standards.
And the best way to iron out any interoperability glitches in a given system,
says Soley, is to build a testbed to see
what works through testing.

36

greater use of the IIoT than is currently


envisioned.
For example, in February 2015, the
IIC announced a track and trace testbed
that Soley says will change the way factory managers manage their plants. In
addition, says Soley, its going to increase
safety on factory floors in ways that nobody could possibly see coming.
Another IIC testbed in progress,
launched in May, is a micro-grid project
designed to do for a connected electric

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

grid what the track and trace testbed is


doing for the use of the IIoT in manufacturing. As this article went to press, the
micro-grid project was finishing the first
of three phases and had the participation
of IIC members Real-Time Innovations,
National Instruments and Cisco.
Designing reference architectures and
running them first in laboratory conditions and then in field trials is the best
way to determine how to get disparate
devices and systems to play nicely together, agrees Nick Butler, group manager for Embedded Systems Product
Marketing at National Instruments.
For the first phase of the micro-grid
testbed, engineers have assembled a
small-scale prototype in a National Instruments lab. The setup incorporates a
pair of National Instruments CompactRIO control and monitoring systems and
takes up the space of one or two desks.
For Phase Two, the testbed will move
to a hardware in the loop (HIL) facility
for further testing and development with
similar electrical loads as it would experience in actual use. The third and final
phase of the testbed project, to be completed by the end of 2016, will deploy an
IIoT-connected solution to an electrical
substation that will bring a new level of
control and monitoring to grid operators.
The standards architectures produced
in the IICs testbeds will be available to
IIC members and any organization that
partners with them.

Security Tops Concerns

Of course, all of these new things going


online represent potentially many more
points of vulnerability where data can be
accessed without authorization or malicious code introduced.
Godfrey Chua, Principal Analyst at
Machina Research, an Internet of Things
advisory firm, says that his companys research confirms that for current and potential users of IIoT-connected systems,
security is one of the biggest concerns.
If we are to continue to maintain the
momentum and accelerate the growth
of IoT, its really incumbent upon the
industry to address the security concerns

Konecranes motto: Not just lifting things, but entire businesses is supported by connections to sensors on over
9,500 of its customers devices, and its use of Siemens PLM Softwares Teamcenter.
that potential customers have. Much of
the concern among IoT users, says Chua,
comes from a shortage of the expertise
needed to address potential risks.
As for addressing those risks, Chua says
that its important to look at entire IoT
architectures rather than to focus solely
on individual components. The fundamental challenge of security and IoT is
that if you look at any IoT solution there
are many pieces, says Chua. These pieces
include the network itself, individual applications, and devices running the applications. The many doorways through
which a malicious actor may find its way
into your solution just makes it harder to
keep up, he adds. For that reason, Chua

recommends taking what he calls a holistic approach to security for any given IoT
solution, by building security in from the
start of the design process, and not to try
to address it piecemeal for each piece of
technology involved.
The good news, says Chua, is that the
technology already exists to build secure
IoT systems. The biggest impediments to
IoT security that he and his colleagues at
Machina Research see are errors of oversight. It could be as simple of forgetting
to implement authentication, says Chua.
To ensure that nothing is overlooked,
and because a given IoT system may
touch many different business functions
including IT, operations, sales, and just

TOP IOT DEVELOPMENT CHALLENGES


SECURITY

35%

COMPLEXITY

26%

CONNECTIVITY

25%

10

Industrial Internet Consortium:


IIConsortium.org

Konecranes: Konecranesusa.com
Machina Research:

20%
20

Michael Belfiores book The Department


of Mad Scientists is the first to go behind the
scenes at DARPA, the government agency
that gave us the Internet. He writes about
disruptive innovation for a variety of publications. Reach him via michaelbelfiore.com.
INFO Cisco: Cisco.com

KEEPING UP WITH TECHNOLOGY 23%


SYSTEMS INTEGRATION

about every other department of an organization Chua envisions the creation


a new executive position that would report directly to the CEO. One of the big
conversations right now in the industry
is whether or not its time for a chief IoT
officer in the organization, says Chua.
Even with standards and best practices
still emerging, the benefits of the IIoT are
already clear. Biased though he may be,
Konecranes Skowron probably speaks for
many when he says: Youd be nuts not to
make sure that the equipment that youre
buying has this technology on it. DE

MachinaResearch.com

30

40

When asked to pick three of the top challenges they face when developing
or planning to develop IoT products, DE readers said security was their No. 1
concern. Source: DE reader survey, January 2015.

deskeng.com /// December 2015

National Instruments: NI.com


Real-Time Innovations: RTI.com
Siemens PLM Software:
Siemens.com/plm

DE | Technology for Optimal Design Engineering

37

HPC Handbook /// Special Section


CHAPTER 4 EXCERPT

Virtualization
Gets Real
Virtual computing can complement
engineers local workstations.

he term virtualization refers to the practice of creating, maintaining, and deploying digital counterparts
or virtual versions of hardware, operating systems, networking environments and storage systems. Constructed largely in software code, these virtual entities have
one clear advantage over their physical siblings: They can
be remotely accessed from anywhere. One type of virtualization that has been steadily gaining ground in the engineering community is desktop virtualization duplicating
the functions of powerful professional workstations in a
virtual environment.

The Dell Workstation Virtualization Center of Excellence


helps software providers and customers move high-end
workloads into a virtualized workstation environment.
Image cortesy of Dell.
By and large, professional design and engineering workload demands workstation-class hardware. Such systems
are configured with the right balance of processing power,
graphics and memory to run industry-standard CAD, CAM
and CAE software. They have also been tested and certified
by independent software vendors (ISVs); therefore, theyre
guaranteed to deliver optimal performance in the chosen
softwares modeling, design and visualization environments.
The drawback, however, is restricted mobility. Workstations
especially the desktop variety are not designed to be
easily portable. Theyre designed to remain fixed in a des-

How the HPC Handbook Works

he Design Engineers High-Performance Computing Handbook is


a multimedia resource consisting of magazine article excerpts;
the hpc.deskeng.com website that is full of videos, case studies and
research; e-newsletters; and regularly released chapters that are free
to download. Once you download a chapter, youll be alerted when new
chapters are ready. Each chapter takes a detailed look at a computing
topic important to design enigneers. The chapters include pictures,
charts, definitions and links to additional information.
The HPC Handbook site is the hub of
information for high-performance computing in design engineering.
The HPC Handbook is
available for download on the site, and the site is constantly
updated to include the latest HPC educational resources that are
pertinent to design engineering teams. It is divided into sections
on Workstations, Clusters/Servers, Cloud Computing and Software,
each of which contain the best information available on the Web
from DE and beyond.
Check it out at hpc.deskeng.com.

38

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

ignated location. Widespread connectivity has freed many


types of workers from the offices and cubicles so they can
work from home, from a cafe, on a train, at the airport
virtually anywhere they can find a reliable web connection.
But this luxury eludes those in engineering who have computing needs that cannot be met with mobile workstations.
Reliance on powerful desktop/deskside workstations means
users must remain physically close to the hardware.
However, in a virtualized environment, an engineer can
work with a virtual machine, configured to deliver the same
computing capacity of a physical workstation. The decoupling of the backend hardware from the frontend access
point is one of the primary advantages of virtualization. In
such a setup, an engineer can experience workstation-class
performance remotely.
The other big benefit of desktop virtualization is realized by IT management. Because the virtual machines are
all under the direct control of IT, its easier to apply updates,
ensure security and quickly fix any issues that might arise.
While some enigneers may balk at losing direct access to
their physical machines, there are a number of enterprisewide benefits that could tip the scales toward virtualization.

Driven by Server-Class Hardware

Contrary to what the name suggests, the virtual desktop infrastructure (VDI) is not exactly a hardware-free environment. Quite the opposite. The VDI has to be built on topof-the-line server hardware, supported by a stack of robust
virtualization software and reliable connectivity. Otherwise,
the subpar experience of the virtual machine would be a

compromise to the engineer whos accustomed to a workstations responsiveness.


If you think hardware vendors might shun the virtualization movement, youd be wrong. Despite their vested
interest in workstation sales, Lenovo, Hitachi, Fujitsu, HP,
Dell, Samsung and other major hardware providers are
regular sponsors of the annual VMworld conference, an
industry event dedicated to virtualization. In March 2014,
Dell launched a new Workstation Virtualization Center of
Excellence and Dell Wyse Datacenter for Virtual Workstations solution, two initiatives that anticipate the growth
of VDI.
We are seeing a change in the way users of data and
graphics-intensive applications are able to securely access
their data outside of the office, said Andy Rhodes, executive director of Dell Precision product line. The idea of
the fixed location-based workstation has changed as users
need to be mobile and collaborate efficiently with others
both within and outside of their organization. Furthermore,
the notion of a 1:1 relationship between a user and a piece
of hardware is going away, as an increasing number of IT
managers see desktop virtualization as a viable means of
providing users with a secure, manageable and resource efficient way to access their desktops and applications.
Every virtual machine in the private or public cloud is
powered by a piece of physical hardware with enough computing resources to support it. VDI isnt seen as the death
knell for workstations. It could be the prelude to an era
where you can access your workstation from any connected
device.

PCoIP, FYI

C over Internet Protocol (PCoIP) is also part of the broader trend freeing the workers from the hardware they
were previously tethered to. Whereas VDI uses clusters to spawn and support a pool of virtual machines (VMs),
PCoIP lets a user directly control a workstation via a network connection. VDI is designed to be one-to-many setup;
PCoIP is intended as one-to-one setup. Currently, Dell offers PCoIP solutions in partnership with Teradici. The solution can be hardware-based (facilitated by a remote-connection card in the system) or software-based.
According to Teradici, the software-based remote experience is ideally suited to small and mid-sized businesses
(SMBs) in architecture, construction, engineering
and manufacturing. Olivier Favre, Teradicis director of product marketing, reveals, The target market for the [software-based solution] is small- and
mid-sized companies with 50-100 workstations.
In the July 2015 issue DE, Contributing Editor
David Cohn observed, PCoIP offers numerous
benefits, including remote access, security,
application independence, local collaboration
and high performance. PCoIP technology
transmits pixels, not data, and even those pixels
are encrypted. Because the software sends pixels
from the workstation display, it works regardless
PCoIP sends pixels from a deskside workstation to zero/thin
of the applications being used and the types of
clients over the network. Image cortesy of Terdici.
content being generated.

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

39

HPC Handbook /// Special Section


CHAPTER 5 EXCERPT

Investing in Workstations
vs. Consumer PCs
You cant do your job if you dont have the right tools

ll professional workstations are computers, but not


all computers are professional workstations. If you
are only running MS Office applications, you can
use just about any computer. But engineers running CAD,
CAE or rendering software, you really should not be using
just any computer. You need a workstation certified to run
your software. Yet many companies provide their engineering professionals with standard consumer-grade personal
computers.
Why? It may be a cost issue. After all, workstations cost
more, dont they? Not really. There is not that big of a
difference in price between entry-level workstations and
consumer PCs that seem comparable on paper, and even
high-end consumer systems are not ideal for professional
engineering work, according to Richard Runnells, director
of Marketing for Solid Edge at Siemens PLM Software.
While in some instances using a high-end consumer
PC or even a gaming PC may work to meet the minimum
requirements for desktop CAD applications, typically these
systems are maxed out and provide little to no room for

What Makes a Computer


an Engineering Workstation?

ngineering workstations are more than just the sum


of their parts. A modern workstation is a balanced
system based on the current processor, memory, storage
and graphics technology needed to run todays CAD,
CAE, and visualization software.
While a PC may have enough power to run CAD
applications, doing so often pushes the PC to its limits.
A workstation, by comparison, typically has power to
spare. Computers typically classified as workstations
have a number of features that set them apart from
general-use PCs:

40

DE | Technology for Optimal Design Engineering

future expansion, he says. The cost of an entry-level


workstation, which comes pre-configured and certified to
run CAD applications, such as Solid Edge, is in many cases
lower in price than that of a top-of-the-line gaming PC.
Jeff Wood, vice president of Product Management for
workstation and thin client business at HP agrees. Buyers
are missing a huge benefit in productivity when they opt for
the consumer PC. The workstations have been highly tuned
for professional applications, he says.

Calculating Return on Investment

The length of time it takes to pay off a new workstation via


increased productivity will vary depending on the amount of
time spent doing design engineering, the engineers salary,
the amount of time saved, and the price of the workstation.
While studies show a wide range of productivity improvements, lets use some conservative numbers and calculate the return on investment (ROI) one might expect
to achieve by upgrading from a PC to a workstation. For
this example, we will assume that our engineers are paid
Error correcting code RAM
Dual processors and multiple processor cores
Optimized graphics processing units
Independent software vendor certification
Workstations are also designed for easy deployment,
maintenance and expansion. Details such as sturdy
handles, easy-to-access hard drives, and other tool-less
features save money and headaches when it comes time
to expand those systems or replace components.
Professional workstations are also designed to
require less maintenance. Workstations can run 24x7,
improving the efficiencies of design engineers by day
and running complex analyses unattended at night,
with less risk of failure

December 2015 /// deskeng.com

a salary of $80,000 per year and spend one-third of their


time actually using CAD software. So $27,000 of their salary is devoted to time spent using CAD. We will also use
a conservative estimate of a 30 percent increase in design
productivity achieved by investing in a new workstation.

Workstation ROI Calculation

Cost of a new workstation: $4,500


Cost of the engineers time: $80,000/year at 250 working
days per year at 8 hours per day= $40 per hour
Time spent doing design work: One-third of an 8-hour
day= 2.64 hours each day
Time saved using workstation: 33% of 2.64 hours a
day = about 54 minutes per day at 250 working days per
year = 225 hours per year
Based on these numbers, the amount that could be saved
annually by upgrading to an engineering workstation can be
calculated as follows:
225 hours per year at $40 per hour = $9,000 per year
Clearly, the engineering workstation can pay for itself.

More Reasons to Upgrade

Even if you already use a workstation, you should seriously consider an upgrade if that workstation is more than three years old.
The larger the model the more time it takes to compute,
manipulate and store on the same system. On older workstations, large models sap your ability to innovate and your
companys ability to compete. By some estimates, CAD
model sizes double every two years, yet most companies
hold onto their workstations for more than four years and
many only update core CAD software every fifth release.
Even if you do upgrade your software more often than
that, you may be paying a huge performance penalty. Installing the latest engineering software on underpowered
hardware can further decrease the speed with which you
design. New versions of CAD, CAE, and visualization software typically offer improved productivity, but software designed to take advantage of the latest advances in hardware
can run slower if you install it on an older computer.
In one study conducted by Lenovo, the company pitted
two similarly equipped workstations against each other running SolidWorks 2013. Both systems had identical amounts
of memory and solid state hard drives. The ThinkStation
S30 completed the identical design task more than twice as
fast as the three-year-old S20.
Giving engineers a new workstation is really the foundation for innovation, says Tom Salomone, Engineering
and AEC and Manufacturing Segment Marketing Manager
at Lenovo. You want them to compute as fast as they think.
You dont want their computers slowing them down.
Similar results have been reported by customers. In a
case study published by Lenovo, the McLaren Mercedes

Formula One racing team upgraded the hardware it uses to


run its CAD, engineering, and simulation software. The design team was expecting modest performance gains of about
2 percent, and they would have been happy with that. We
have come to realize that we may have massively underestimated this, said Alan Dueden, lead systems engineer at the
McLaren Technology Center. A figure 10 times that might
be a little nearer to the mark. Their MIDAS simulations
were 30 percent faster, assembly drawing changes improved
25 percent, and parametric updates were 60 percent faster.
Quite simply, the right tool for an engineers job is a
professional workstation. Without professional workstations, a companys innovation engine is stalled. The engineers pace of work gets reduced to match the sluggish
speed of outdated or inadequate hardware. Yet workstations
are more capable and affordable than ever. Their return on
investment is outstanding.
For design engineers, a professional workstation means
more time spent creating new products and improving existing ones and less time spent waiting for large assemblies
to load or simulations to run. For IT specialists, equipping
power users like design engineers with professional workstations means less time spent diagnosing and fixing issues. And
for executive management, investing in an affordable professional workstation can pay for itself in a very short time.
The decision to invest in a professional engineering
workstation is not just about the bottom line. Its about
making better designs, speeding up the design cycle, and
growing the business.

Learn More

o learn more about


building a balanced
workstation and parallelization, download The
Design Engineers HighPerformance Computing
Handbook, which has
just been updated with
two new chapters covering those topics. The full
version of chapters 4 and 5 include a discussion of
the benefits of error-correcting code RAM, dual processors, GPUs, ISV certificatons, ROI justifications,
definitions of terms and more.
This free resource, brought to you be DE in partnership
with Intel, is available at hpc.deskeng.com/download.

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

41

Focus on Optimal Design /// Connectivity

Intelligence and
the Connected Car
Networking, software and powerful processors continue
to transform our primary mode of transportation.
BY PETER VARHOL

Is it a car or a
computer? Its both.
Image courtesy of NXP
Semiconductors N.V.

fter decades of incremental improvement in visible


technology, the automobile has undergone drastic
changes in the last 10 years. Perhaps the most significant of those changes is the incorporation of connectivity, including Internet access and wireless data communications: the connected car.
The connected car includes music and audio, smartphone
apps, navigation, roadside assistance, voice commands, contextual help/offers, parking apps, engine controls and car diagnosis
functions. Further, driver assistance and even driverless cars are
transforming the story of personal transportation. It will take
a decade or more to approach that goal, but the fact that it is
within reason is a testament to the tremendous advances in automated control and connectivity.
More vital uses of automotive intelligence and connectivity include diagnostics and prediction. By providing more detailed data and better ways of analyzing that data, automobile
performance can be optimized and potential problems can
be predicted. Further, automated decisions can be made in
real time, enabling the vehicle to quickly adapt to changing

42

DE | Technology for Optimal Design Engineering

technical or environmental situations.


Driving these changes is a combination of high-performance
embedded processors, unique computing and software innovations, a vision of networking between previously separate automotive systems, and the addition of wireless communications
to deliver engineering innovations to the driving experience.

Connected Systems in the Car

Just what is connected? Its useful to divide this phrase into


three distinct categories: connected within the car; connected
between car and a back-end computing infrastructure; and connected with other cars. These categories represent the major
initiatives for the automotive industry in terms of connectivity,
and also involve different goals and technologies.
Connected within the car is farthest along. Most current
model cars have multiple processors, and are using the legacy
CAN (controller area network) bus for connectivity. A CAN
makes it possible to move data around reliably, so that data
can be shared between automotive subsystems. For example,
the engine emission sensors send data to instruments detailing

December 2015 /// deskeng.com

measurements of gasses, which are evaluated and presented to


indicator lights and to instruments that are used in service facilities. This data is usually transmitted on the vehicle CAN bus
between engine systems, emission monitors and displays.
The ability of cars to exchange data between different subsystems provides for greater analysis, information and reaction
between systems that can work interdependently. The drivetrain
would benefit from real-time data on engine operation. Different sensors at different points within the engine can provide a
mixture controller with a finer degree of data on fuel consumption, providing for a level of fine-tuning that simply was not
possible a few years ago. This type of control is enabling higher
fuel economy, less engine wear and fewer emissions.
However, CAN is limited in bandwidth, and cars are in need
of greater bandwidth and connectivity than CAN is able to provide. With an average of 50 or more processors on a car, the
amount of data processed has grown enormously in the past few
years. Some of these are standard embedded processors, while
others are specially designed using FPGAs (field programming
gate arrays) or ASICs (application-specific integrated circuits).
Its not unusual for a new car to have hundreds of pounds of
electronic components monitoring and controlling engine performance, fuel mix, brakes, power, drivetrain, and a host of other
activities. Hybrid and electric cars have still more electronics.

250

million cars will


include some form of
embedded technology
by 2020.
Gartner Research, January 2015

autos perimeter. Initial tests indicate that they may have safety
advantages over cars with human drivers, in large part because
they are able to detect and react to external activities, such
as other cars and pedestrians. With highly accurate maps and
GPS, cars navigate between points and avoid obstacles.
But car-to-car communication makes this possible on a
much larger scale. Cars within proximity to each other can exchange sensor data as well as velocity and direction. Think of
it as choreography, with many cars communicating constantly
in order to navigate while avoiding each other.
Getting there will be a long and involved process. While
sensors and high-performance processors make this feasible
today, it could be decades before enough autos possess the
technology to make it worthwhile to use car-to-car communications for practical purposes.

Aggregating Data Off the Car


As off-car analytics become increasingly important in analyzing and optimizing auto performance, bandwidth needed to
connect many cars to a central server infrastructure will likely
operate alongside the CAN bus controlling in-car connectivity. Only a subset of auto data will be sent off of the car, and
it is more likely that this connection will use protocols that
better support traditional IT operations.
Car-to-server connectivity offers the best opportunity for
near-term enhancement of automotive electronics, feedback,
and improvements in car operations. Car-to-server refers to
the ability of many individual cars to send data from the car
to a central location in the cloud. The purpose of this data
can be multifold. Data aggregated from many cars can be
used for a variety of analytics. Once we better understand
events leading up to failures, we can use that data to predict
failures in individual cars, says Wenis Jin, automotive industry manager at MathWorks.
And data will go both ways. Once there are good data models, centralized applications can inform users to obtain service.
We could also make adjustments to systems, by downloading new software or changing parameters, says Jin. Outright
failures are uncommon, but they are drastic events for drivers.
We can make them even less common.
Car-to-car connectivity may be the level of communication required to produce self-controlled (or driverless) cars.
Today, the driverless concept cars on the road operate through
a combination of real-time GPS updates and sensors on the

Personal CNC
Shown here is an articulated humanoid
robot leg, built by researchers at the Drexel
Autonomous System Lab (DASL) with a
Tormach PCNC 1100 milling machine. To
read more about this project and other
owner stories, or to learn about Tormachs
affordable CNC mills and accessories, visit
www.tormach.com/desktop.

deskeng.com /// December 2015

PCNC 1100 Series 3

Mills shown here with


optional stand, machine
arm, LCD monitors,
and other accessories.

PCNC 770 Series 3

www.tormach.com/desktop

DE | Technology for Optimal Design Engineering

43

Focus on Optimal Design /// Connectivity

The Audi tablet includes gesture controls, 3D sound for a


concert-hall atmosphere in the car, the Audi phone box
and the seamless integration of smartphones into the car.
Image courtesy of Audi.

Visa, Pizza Hut and Accenture are developing a connected


car commerce experience to test mobile and online
purchases on the go. Image courtesy of Business Wire.

Distracting, but Enhancing the Driver

204%

One legitimate concern surrounding the connected car is that


the many features enabled by connectivity might serve to distract the driver from his or her primary responsibility of driving
the car. While its true on one level, on another its made driving
safer by taking more decisions out of the hands of the driver
and automating them, and making the cars safer by improving
diagnostics and predictability.
That starts with collision warnings, based on sensors on the
perimeter that detect close objects and those closing in on the
vehicle. This involves the use of sensors on the perimeter of the
vehicle. Collision avoidance follows, with cars having the ability
to brake automatically, or turn to avoid obstacles. Multiply this
by hundreds of cars in the immediate vicinity and youll see how
safety is being significantly improved.
Maintenance and optimal performance are also improved
through the use of analytics. Cars can be made more efficient
through monitoring and feedback of data from engines, drivetrains, brakes, and other systems susceptible to wear and eventually failure. Informing cars and drivers of impending failures
and even possibly downloading fixes is fast transforming
the transportation experience.

The Technology Behind the Automobile

What makes these innovations possible? One is the use of inexpensive multi-core processors that provide for multiple independent tasks to be performed by a single processor. This architecture provides a higher level of computational capability and
performance, the ability analyze data, and respond in real time.
Graphics processors are also making a significant impact. The four-core NVIDIA Tegra K1 mobile processors
are driving instrument and navigation displays, for example. NVIDIA processors can also be used for fast-floating
point operations in general, expanding their use into data

44

DE | Technology for Optimal Design Engineering

Amount that
revenue from all
digital auto content
(entertainment, safety, vehicle
management, etc.) is expected to
grow between 2016 and 2021.
PwCs Connected Car Study, 2015

processing and decision making.


Cloud computing is also contributing to auto connectivity.
Virtually unlimited processing power on the back end makes it
possible to gather data from cars, aggregate it and provide data
for diagnostics, prediction and future car designs.
There is no turning back the clock on the connected car.
Electronics, software and networking have only started to
scratch the surface of what is possible. There will be new and
different issues as our cars start looking more and more like
computers, but the overall effect will be positive on both the
industry and the user. DE
Contributing Editor Peter Varhol covers the HPC and IT beat
for DE. His expertise is software development, math systems,
and systems management. You can reach him atde-editors@
deskeng.com.

INFO MathWorks: MathWorks.com

NVIDIA: NVIDIA.com
NXP Semiconductors N.V.: nxp.com
For more information on this topic, visit deskeng.com.

December 2015 /// deskeng.com

Additive Manufacturing

/// Focus on Optimal Design

3D Printing Clocks In
Additive manufacturing will be a part of more shop floors in the future,
and it will change the design for manufacturing process.
BRIAN ALBRIGHT

ost of the media buzz around 3D printing/additive


manufacturing (AM) technologies has centered on
the home or small-shop-based maker. But the biggest driver of what the Wohlers Report estimates to be a $4.1
billion market for AM services and products, has been its
integration into traditional manufacturing workflows.
Manufacturers are moving well beyond rapid prototyping (although that is still an important application) and using 3D printing for fixtures, jigs, mold and die creation, tooling, and to create
finished parts. That is happening across multiple industries, most
notably in auto, aerospace and in the medical/dental markets.
The accelerated growth that weve seen over the last several
years has been the adoption of the technology on the production floor, and we see that as being the largest opportunity as we
look out over the next five to 10 years, says Rich Garrity, vice
president and general manager of vertical solutions at Stratasys.
In almost all of these use cases, 3D printing has been integrated into existing workflows, augmented by additional processes like machining, forging, molding, etc. Its just like having
another tool in your toolbox, says Patrick Dunne, director of
industrial 3D printing applications at 3D Systems. Like any
manufacturing process, it will be part of a combination of different tools that are selected to make something.
It is also changing the way engineers design parts, assemblies
and finished products. AM makes it possible to create complex
geometries that either would have required multiple pieces in

Cincinnati Incorporateds Big Area Additive Manufacturing (BAAM) system has been used to produce Local
Motors Strati, a full-size Shelby Cobra automobile, a
scaled fighter jet, a 12-ft. kayak, and more.
the past, or that werent possible at all using traditional processes.
Limitations on what can be fabricated are rapidly falling away,
and that will require a new approach to design and the ability
to incorporate more rapid iteration and optimization processes.
For subtractive processes, a number of design rules are
taught and those dont apply to additive manufacturing, says
Andy Snow, senior vice president at EOS. There is a greater
level of freedom of creation.
3D printing presents two key value propositions when it
comes to manufacturing. First, it enables the mass production of
custom pieces, although these are not always finished products.
Orthodontics manufacturer Invisalign, for example, uses printers
from 3D Systems to create thousands of custom aligner models.
Those models are used for thermoforming the final dental aligners. What they are doing is mass custom manufacturing of disposable tooling, Dunne says. The largest adopters of 3D printing are not using the printers to make the final product, but are
making an intermediate product in the manufacturing process.

Customization and Complexity

The sweet spot for AM now is in low-volume, high-complexity


structures an extreme example of which is the Strati, the 3Dprinted concept car that Local Motors assembled at the International Manufacturing Technology Show (IMTS) in 2014 using

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

45

Focus on Optimal Design /// Additive Manufacturing


Integrating Additive

These direct metal laser-sintered parts, additively manufactured via an EOS M 290 system, have been grown
onto small sub plates. This System 3R palletization concept allows parts created via AM to remain on sub plates
through the balance of the machining process.
Image courtesy Georg Fischer Machine Systems (GFMS).
the Big Area Additive Manufacturing Machine (BAAM) from
Cincinnati Inc. created at Oak Ridge National Laboratory.
The Strati demonstration simultaneously proved the notion
that you can print an entire car (minus the tires, the powertrain,
and a few other components) and highlighted some of the limitations of the technology. A Toyota factory is unlikely to churn
out 50,000 vehicles per year using the same techniques.
But the Strati does represent an economical way to create a
completely custom vehicle. Local Motors is turning its attention
to what Alex Fiechter, head of product development at Local Motors, refers to as the nitty gritty of developing design rules and
best practices for the additive processes used on the Strati. There
will be more materials testing and crash simulations, for example,
as well as investigating different production processes.
We still have a lot of work to do on our printed vehicle, but
its very illustrative of what can be done, Fiechter says. Even as
we look at the possibility of embedding structural elements into
the car, its a much easier situation for us because we can embed
the assisting componentry to create a full, enclosed part as the
car is being created. You couldnt do that with another process.
Starting next year, GE Aviation will roll out its CFM LEAP
engines the first aircraft engines to include 3D printed parts.
In this case: 19 fuel nozzles that the company says could not
be produced using traditional techniques. The nozzles are 25%
lighter than their predecessors, and will be made in a single
piece (compared to the 18 parts previously required). A more
intricate design also provides five times higher durability.
Thats a good example of the types of opportunities AM opens
up for design iteration and optimization. Theres almost no correlation between cost and complexity, Dunne says. You get step
changes in efficiency and optimization of the product itself.
Manufacturing engineers have traditionally had to compromise on designs to make it possible to fabricate an assembly in
a cost-effective manner. 3D printing allows engineers to design
for pure functionality and ignore other constraints. Its like putting accelerant on design optimization and iteration, Dunne says.
You can review a concept within hours of designing it.

46

DE | Technology for Optimal Design Engineering

Using 3D printing and additional manufacturing processes to


complement each other is the way forward, according to Snow at
EOS. The company recently partnered with George Fisher Machining Solutions (GFMS) to integrate additive manufacturing
machines into the production of mold inserts. Were integrating additive into the overall process chain, Snow says. Were
integrating what we call the GFMS System 3R approach, which
is a highly accurate reference system that links all the machines
in a workshop with a common reference, enabling seamless, automated transfers from machine to machine.
The two companies have introduced the AgieCharmilles
AM S 290 system, which produces molds and dies using metal
laser sintering. It allows mold makers to move thermal exchange
closer to the surface of a mold. It can be integrated with other
GFMS machine tools and measuring devices.
Alcoa, a company that has rested its fortunes on traditional
manufacturing, is expanding an R&D center in Pennsylvania
to accelerate development of 3D printing materials and processes. The company hopes to cash in on demand for complex
3D-printed metal parts for aerospace, automotive, medical,
construction and other applications. Alcoa sees the integration
of additive and traditional processes as a key strategy, exemplified by its Ampliforge process, which involves printing a near
complete part and then treating it with a process like forging to
increase part strength. The process is being tested at facilities in
Pittsburgh and Cleveland.
Again, the key contribution of AM in these scenarios is the
ability to create more complex parts as a single unit. The power
of additive manufacturing really starts in the design process,
Stratasys Garrity says. If a company is looking to just replace a
traditionally made part with a printed part with the same design,
often it doesnt make sense.
Benefits come from freeing up the engineers to design better
parts, regardless of the manufacturing process. You can design
structures with lattice interiors to get weight reduction, Garrity
adds. Aerospace and auto manufacturers are under pressure to
meet weight requirements, so that is a big benefit for them.

Prototypes to Finished Parts

Even the idea of rapid prototyping, a longstanding AM application, is starting to work its way into finished products.
According to 3D Systems Dunne, automakers are using 3D
printed components to help shave time from their go-to-market
cycle. The long lead-time on creating injection mold tooling
for nylon parts in a vehicle can add weeks to the launch cycle.
By printing a run of those parts up front, they can launch the
vehicle while the tooling is being produced. Time is money, so
while its more expensive to create nylon parts on a laser sintering machine, theres still an economic justification for that type
of bridge tooling because they get to market sooner, he says.
Jigs, fixtures, tooling and other secondary manufacturing
equipment are another key area where 3D printing has flour-

December 2015 /// deskeng.com

Additive Manufacturing

55%

/// Focus on Optimal Design

of DE readers surveyed
are using or plan to use
3D printing for end-use
parts or products.

DEs The State of the 3D Printing Solutions


Market report, sponsored by Stratasys

ished. We see it put ion the production floor to customize jigs


or fixtures for a particular line process or for the ergonomic
benefits of the line workers, Garrity says.
In aerospace, composite tooling and molding are allowing
manufacturers to create more complex shapes and to more easily change or reproduce those shapes with less investment.
That also adds to the direct part side of the equation, because that ability to make new geometries has an even larger
impact. You are forced or encouraged by the technology reevaluate how youve broken that product up, Fiechter says.
And the direct part side of the equation is getting bigger. The
Airbus A350 XWB uses more than 1,000 3D printed parts, Honeywell International is testing a 3D printed heat exchanger, and
GE Aviation, Pratt & Whitney and other companies are also putting printed parts on their planes. AM revenues in aerospace are
expected to reach $1.7 billion in 2020 and expand to $3.3 billion
in 2022, according to SmarTech Markets Publishing.
The United Launch Alliance, a joint venture of Boeing and
Lockheed Martin, is testing additive manufactured parts for
rockets. The ventures Atlas V and Delta IV rockets will include
components printed on Stratasys Fortus 900mc equipment with
ULTEM 9085 material.
Being able to produce limited access or blind geometries
forces engineers to look at the functional duties of every element of a vehicle, for example, and divide those functions differently across a given part. Instead of an exterior panel simply
serving an aesthetic purpose, it can also provide ergonomics and
include a body structure for crash absorption, Fiechter says.

The biggest barrier, however, is a lack of familiarity


among engineers and manufacturing executives. Designers
just need more experience and familiarity with the process,
Garrity says.
EOS has introduced its Additive Manufacturing Consultancy to provide that type of education to clients, including
everything from simply introduction to the technology up to a
complete assessment of the business. EOS is also working with
Underwriters Laboratory on its AM educational efforts. DE

Brian Albright is a freelance journalist based in Columbus, OH. He


is the former managing editor of Frontline Solutions magazine, and
has been writing about technology topics since the mid-1990s. Send
e-mail about this article tode-editors@deskeng.com.
INFO 3D Systems: 3DSystems.com

Cincinnati Inc.: e-ci.com


EOS: EOS.com
Local Motors: LocalMotors.com
Stratasys: Stratasys.com
Underwriters Laboratory: industries.ul.com
Wohlers Associates: WohlersAssociates.com

Materials, Education Remain Obstacles

There are still challenges for firms trying to integrate AM on


the plant floor. One obstacle is material selection. For some
applications, there arent always appropriate materials for the
existing printing processes, or the processes are too slow.
There is certainly metallic 3D printing, but the deposition rates are much lower than with polymers, so you butt up
against that issue of speed, Fiechter says. Cars are built on top
of structural steels for safety and crash energy absorption. Now
you have to rewrite the book, and find media that can be run
through this process with a new type of machine and method
of deposition yet still functionally perform the same way.
There also needs to be more integration with manufacturing
systems, as well as tools to can make it easier for designers to
determine which parts make sense for additive.
deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

47

Focus on Optimal Design /// Software Licensing

The Dawn of
Pay-As-You-Go CAD
Does the shifting of CAD licensing signals the beginning of a new era?
BY KENNETH WONG

arlier this year, just a week shy


of Valentines Day, Autodesk signaled the perpetual licenses twilight: New commercial seats of most
standalone desktop software products
will be available only by desktop subscription beginning February 1, 2016,
the company declared. In doing so, it
publicly crossed the point of no return.
In enterprise, consumer and product lifecycle management (PLM) software sectors, brands like Salesforce,
Norton Antivirus and Arena Solutions
have proven subscription licensing to
be a viable, sustainable model. But in
the design and engineering software
market, the status quo is perpetual licensing. Here, subscription remains
a touchy subject; it still raises eyebrows and blood pressure.
Its opponents see subscription licensing as a way for some
vendors to keep the users on a long leash, hold their proprietary data hostage, and collect fees indefinitely. Others may
welcome the subscription model because the pay-as-you-go or
pay-per-usage option gives them instant access to the software
at a much lower cost.
According to Jon Peddie Researchs 2015 CAD Report, Autodesk accounts for 29% of the $8 billion CAD market. As such,
the company carries a lot of weight. When it makes a major
policy shift, it tends to produce repercussions across the market.
Its decision to fully commit to subscription is closely observed
by its partners, customers, resellers and even rivals, because everyone has some skin in the game.

The Long Goodbye

In September, Andrew Anagnost, Autodesks senior vice president of Industry Strategy and Marketing, began talking to the
press to clarify how the company intends to handle the existing
perpetual license owners. He assured them that customers who
have bought perpetual licenses will continue to get updates for
as long as they are on maintenance.

48

DE | Technology for Optimal Design Engineering

SOLIDWORKS Mechanical Design (initially introduced


as Mechanical Conceptual) goes on sale via quarterly
and annual subscriptions. The new licensing model is a
departure from traditional perpetual desktop licenses.
Image courtesy of SOLIDWORKS.
Some buyers began stocking up on perpetual licenses to beat
the imminent cutoff date, Anagnost acknowledged. But not as
much as we thought we might see, he says. In many regions,
the opposite happened. In Australia and New Zealand, we
stopped selling AutoCAD LT [via perpetual licenses] last year.
But what happened was that the number of people buying AutoCAD LT went up after that, Anagnost says. The implication
is that the lower upfront cost in subscription is enticing more
buyers to pick up the software.
Whereas Autodesk is jumping in with both feet, Dassault
Systmes took a more cautious approach. SOLIDWORKS,
Dassault Systmes rival product to Autodesk Inventor, remains
a desktop product for perpetual licensing. The majority of our
SOLIDWORKS customers want to buy perpetual licenses.
Our customers prefer to own our best-in-class design software
where they create their IP (intellectual property), says Kishore

December 2015 /// deskeng.com

Boyalakuntla, senior director and leader of Product Management for SOLIDWORKS.


Adopting a hybrid approach, Dassault Systmes began offering its two newer cloud-centric products Industrial Designer and Mechanical Designer as quarterly and annual
subscriptions. The announcement was made at the SOLIDWORKS World 2015 user conference. The Lighthouse customers [with early access] told us [Mechanical Conceptual] is
not a tool theyll use for only one month or two. Theyll do
concepts all year long, so theyre already committed to a yearly
lease. [The subscription term requirement is] not an issue for
them. But maybe well see other smaller customers and independent designers whore not like that. Were all going to
learn from this, and well adjust if needed, said Bertrand Sicot,
former CEO of SOLIDWORKS.

Going After the Non-Committal Buyers

In September 2013, Siemens PLM Software tiptoed into subscription by introducing a monthly licensing option to its mainstream CAD program Solid Edge. Prices range from $100 a
month (design and drafting only) to $400 a month (comprehensive 3D CAD with support contract).
Kris Kasprzak, Siemens PLMs marketing director at the
time (currently product manager for NX), explained: A typical
use case might be a government contractor who needs to work
on a project for six months. They dont want to buy the software, but want to be able to pay for it for using it six months. Or
start-up companies without a lot of money. They can use Solid
Edge on subscription until theyve made it and realized theyll
need to use it perpetually. Or businesses that are cyclical, like

Subscription vs. SaaS

lmost all browser-based, cloud-hosted softwareas-a-service (SaaS) offerings are sold as subscription software ... but not all subscription
softwares are browser-based, cloud-hosted SaaS titles.
Adobe has moved all of its individual titles and suites
such as Photoshop, Illustrator and Creative Suite to
the subscription model. But theyre not delivered as
browser-based software. Users install the software on
a local machine to use it. As long as the subscription is
active, the software remains operable.
CAD titles currently offered under subscription
like Autodesk products and Solid Edge from Siemens
PLM Software work the same way. They require a full
installation; you cannot use them from a browser the
way you would most SaaS products. Onshape, founded
by former SOLIDWORKS veterans, stands out as an
exception to this. The software is a full-fledged CAD program that runs in the browser (no installation needed).
As a truly functional SaaS CAD product, it earns the right
to introduce the acronym CaaS (CAD-as-a-service).

29%

of the $8 billion CAD


market is attributed
to Autodesk.

Jon Peddie Reseachs


2015 CAD Report

toy manufacturers whore on fire during holiday seasons, then


have less work later.
Solid Edge subscription and perpetual license options are
still available from Siemens. Some of our customers have a
strong preference for one or the other type of license. We anticipate the interest level in subscription to be fluctuating in some
of our core markets and intend to continue offering customers
the choice of model, says Dr. Stefan Jockush, vice president of
Strategy for Siemens PLM.
PTCs Windchill PLM products were previously available
as software-as-a-service (SaaS) offerings through partners like
NetIDEAS. But after acquiring NetIDEAS last year, PTC
launched PLM Cloud. More recently, the company began offering a subscription option for all its software, including its
CAD program Creo. According to the companys FAQ, initial
subscription terms are one, two or three years, depending on
the solution chosen.
Stan Przybylinski, vice president of Research at CIMdata,
says, There are still people who want to have the software forever, but we increasingly live in a subscription world now, driven
by the Web and apps, so it is natural that people want to have
that experience at work.
Offering subscription licensing does come with certain risks
for the vendors. For one thing, customers are not obligated to
remain on subscription once the project has run its course.
People can always walk away each year, but we know that in
practice that does not happen often. Whether you like it or not,
your information and business gets locked into the tools of your
chosen providers, says Przybylinski.

Starting Over From a Blank Sheet

In March, a group of former SOLIDWORKS veterans


launched a new CAD brand titled Onshape. As it turned out,
being a newbie in a mature market wasnt a handicap but
an opportunity. The company wasnt saddled with an existing customer-base entrenched in perpetual licenses; nor did
it have a legacy code originally developed for the desktop
PC environment. This allowed the startup to do what most
established CAD vendors couldnt or wouldnt do. It architected its CAD package to run in the cloud; and it offers the
product on subscription.
Jon Hirschtick, co-founder of SOLIDWORKS, now runs
Onshape as the companys board chairman. On the companys
blog, he wrote: Younger people have grown up in a post-desk-

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

49

Focus on Optimal Design /// Software Licensing

Autodesk began nudging its customers toward subscription


licensing by announcing Feb., 1, 2016, as the end date for
perpetual desktop licenses. Image courtesy of Autodesk.
top world and have different expectations about computers. They dont even think about having a computer. They
walk in with their laptops and their tablets and their mobile
phones. They expect computing to be modern and available
anywhere, any time on any device. Cloud, Web and mobile
technologies are our exciting new raw materials for creating CAD. Onshape subscriptions begin at $100 per user,
per month. A free version with limited private storage is also
available for students and makers.

CAE Edging Toward Flexible Licensing

A handful of CAE or simulation software vendors currently


offer SaaS. SimScale, for example, markets its browser-based
simulation software to individuals for as little as 200 (about
$215) per month. But the majority still sells perpetual licenses
for desktop or server installations or uses a token-based system.
If the CAD market gradually migrates toward subscription, will
CAE follow in its footsteps?
A lot of our customers, whether theyre enterprise customers or small businesses, are interested in this pay-per-use or payas-you-go option what we call elastic licensing. However,
its still very new in CAE, says Ray Milhem, vice president of
Enterprise Solutions and Cloud at ANSYS.
Milhem attributed the change in software users attitude toward subscription or on-demand licensing to the introduction
of remote computing and cloud computing. He says, People
are beginning to ask for elasticity not just in their compute capacity but also in their licensing.

50

DE | Technology for Optimal Design Engineering

ANSYS recently began offering its Enterprise Cloud option, which runs on Amazon Web Services (AWS). The company writes, Customers who adopt the ANSYS Enterprise
Cloud can scale their simulation capacity including infrastructure and software assets on-demand. It brings ANSYS
one step closer to the on-demand model. Companies like Rescale also offer simulation infrastructure (software-hardware
combination) available on demand, spawning the new term
PaaS (platform-as-a-service).
The leading and exciting offering we have right now at
ANSYS is single-tenant cloud (STC) setup, says Milhem.
Were working on a new generation that will be multi-tenant
cloud (MTC). But SaaS for CAD and SaaS for CAE may not
be identical, he cautioned. For our industry, the elastic model
we offer is SaaS-based, because you only use it for as much as
you need to, and you pay per hour usage. Both STC and MTC
are complementary and are targeting different markets, he says.
Milhem specified that ANSYS elastic licensing will complement the companys existing offering of leased and paid-up licenses. Our customer base and future customers have options
and will choose what fits their needs, he adds.

Redefining the V in VAR

When perpetual licensing was the default purchase option,


CAD vendors relied heavily on resellers, or value-added reseller (VAR) networks. In addition to selling the software, VARs
usually operate as first-level support providers. They also offer
training, consultancy and complementary services. With perpetual licenses typically priced between $1,500 to $4,000, VARs
stand to generate significant revenues by nurturing a pool of
core accounts.
Subscription commerce, however, is drastically differ-

December 2015 /// deskeng.com

ent. The emphasis is on low prices (around $100 per user per
month) and volume sales. Online software distribution sites like
Novedge have proven that design and engineering software can
be marketed just like books on Amazon.com. It challenges the
conventional thinking that VARs are essential to the transaction.
Therefore, the VARs role in the new era needs to be calibrated.
The VARs still adding value will have a sustainable relationship with their customers. They may even have more
opportunities to generate revenue because of the different
types of cloud software customers will be deploying. Smart
partners will figure out ways to help customers integrate
products, says Anagnost.
Even with a hassle-free browser-based product like Autodesk PLM 360, VARs can still offer services, because PLM
requires an understanding of the customers processes and what
theyre trying to accomplish. VARS can help them integrate [the
PLM modules] with other enterprise systems and create templates, says Anagnost.
Anagnost suggests forward-thinking VARs should get ready
for the volume-sales model. He asked, rhetorically: What good
is a high margin business if its shrinking? Watch where the volume is going. The volume is moving toward the new model,
not the old model.
Siemens PLMs Jockusch says, Keep in mind that the purpose of a reseller is to add value to the product they are selling,
thus, the term value-added reseller. As long as resellers provide real added value to customers, such as services, training
and consulting, their role doesnt fundamentally change with a
subscription model.

time ownership. The perpetual license ensures the software


will remain in their possession even if the original developers
fortune falters or fails.
But a new class of software users trained on SaaS challenges this established notion. They view software as a means
to an end, a digital tool to get the job done. For them, extending the cost of ownership beyond the usefulness of the tool
doesnt make sense. (In the design and engineering software
market, the cost of ownership comes in the form of annual
maintenance fees and renewable support contracts, which
can certainly add up over time.) Subscription advocates like
Autodesk and Onshape are counting on the Id-rather-rent
crowds growth to outpace the Id-rather-own crowd. DE

Kenneth Wong is Desktop Engineerings resident blogger


and senior editor. Email him at kennethwong@deskeng.com or
share your thoughts on this article at deskeng.com/facebook.

INFO ANSYS: ANSYS.com

Autodesk: Autodesk.com
CIMdata: CIMdata.com
Dassault Systmes: 3ds.com
Jon Peddie Research: JonPeddie.com
Novedge: Novedge.com
Onshape: Onshape.com
Rescale: Rescale.com
Siemens PLM Software: Siemens.com/plm
SimScale: SimScale.com
SOLIDWORKS: SOLIDWORKS.com

SPOTLIGHT

Owners vs. Renters

Perpetual licensing is attractive to those who view software


as an asset. For such buyers, the comparatively higher upfront cost is well worth the assurance that comes with life-

For more information on this topic, visit deskeng.com.

SPOTLIGHT
APEXX 1 & renderPRO 1
When you pair the worlds smallest overclocked

Directing your search to the


companies that have what you need.

Millions of FREE CAD Models

workstation with the worlds smallest desk side


rendering solution, youll take your Autodesk
workow further and faster than ever before.
With each chassis only 4.7 inches wide, 8.5
inches tall, and 9.0 inches deep, the

The fastest way to model


a part is to download it!
Millions of supplier certied models
All CAD formats, all FREE

ultra-compact, stackable, liquid-cooled APEXX 1


and renderPRO1 are the revolutionary combo

that will keep you creating and never waiting.

Call : 888-984-7589
Click : www.boxxtech.com
Intel, the Intel logo and Iris are trademarks of Intel Corporation in the U.S. and/or other countries.

deskeng.com /// December 2015

For those who create in 3D

www.3DX-US.com

DE | Technology for Optimal Design Engineering

51

Focus on Optimal Design /// Education

Learning to Use the


Black Box Correctly
Professors and employers discuss the role of software in STEM education.
BY KENNETH WONG

he engineering director of Simulation-Based Design at


Whirlpool Corporation, John Mannisto, reveals what he
looks for in new recruits. A Ph.D. isnt necessarily going
to persuade him to give you a job. The ones Im interested
in may only have a bachelors degree or a masters, but theyve
had experience designing airflows in manifolds and engines, he
says. They dont necessarily understand how the computation
works in the software code, but they can get the job done.
Mannistos approach reflects the pragmatism of a hiring
manager. He wants new hires who can hit the ground running.
But university educators say they need to be teaching more than
software skills in engineering curriculums.
Students are using numerically based software, but theyre
using them with very little numeric background, says David
Auslander, professor of Mechanical Engineering at UC Berkeley.
To him, thats a disconnect between the tool and the user. Hed
like to teach students to include numerical approaches from the
beginning for such basics as integrals and derivatives so they understand the underlying principles of simulation software.
Most employers prefer graduates with software mastery. But
many educators feel that, without a thorough understanding of
the mathematical principles and engineering rules, software mastery rings hollow, perhaps even dangerous. At the heart of this
debate are the two different views of the softwares role: Trust the
software like a black box that can spit out the correct answer; or
peek inside the black box to learn how it produces the answer.

Recalibrating the Curriculum

Auslander specializes in automatic control system analysis and


design, computation for physical system simulation and for control system design and implementation, building energy management, and mechanical system control. He has served as associate
dean and acting dean of UC Berkeleys College of Engineering.
In the past, you needed ways to generalize and analyze
problems because dealing with them purely with computation
was too expensive, Auslander says. In Newtons era, computation was expensive. In the Manhattan Project [1940s], they
had to employ human computers people who manually performed computing to deal with the intractable calculation
problems they encountered.

52

DE | Technology for Optimal Design Engineering

Students in FIRST Robotics programs use system


modeling software, engineering calculation
packages and CAD programs to solve engineering
challenges. Image courtesy of FIRST Robotics.
However, the cost of computation drastically decreased once
computers became widely available. Harvesting the horsepower
of multicore processors, software like Wolfram Mathematica or
MathWorks MATLAB can now compute what was previously
considered impossible or impractical with hand calculation. Yet
basic engineering curriculums still feature largely a bunch of
special cases for which computation was not available at the
time. Theyre about 50 years out of date, says Auslander.
To realign engineering education with the type of complex
problems students will likely be called upon to solve, Auslander
suggests turning the curriculums inside out. The role of software training in engineering education is a hot button issue,
he says. The curriculum is not preparing the students to know
how to use these types of analytical software.
Hed like students to have an intuitive understanding of the
math working behind the scene, the analytical algorithms in software. You have to teach things that are numerically based from the
beginning, he says. Otherwise, he asks, How would they know
when theyre getting nonsense and when theyre getting real results? How can they formulate a problem in numeric terms?
Auslanders concern is echoed by Dr. Paul Lethbridge, academic program manager at ANSYS. If you teach someone how
to use the product only, youre teaching them the black box

December 2015 /// deskeng.com

approach, he says. If they dont understand whats going on


inside the black box, then its garbage in, garbage out.

Teaching Skills While Remaining Brand-Agnostic

Most software vendors have outreach initiatives targeting colleges


and universities. From the vendors point of view, building brand
familiarity among aspiring engineers is a worthwhile investment.
Autodesk, for example, offers free education licenses of its design and engineering software. Dassault Systmes, Siemens PLM
Software and PTC have robust educational licensing policies to
provide their software to students at heavily discounted rates.
Despite access to commercial code, educational institutions
have to narrow the number of software they teach in a course
or the volume of software could overwhelm the materials. Some
universities have adopted a brand they feel represents the norm.
We have effectively adopted ANSYS as our CAE platform, says Dr. Rajesh Bhaskaran, senior lecturer for Cornell
Universitys Mechanical and Aerospace Engineering department. Were using it in about 11 courses, both at graduate
and undergraduate levels. But we dont teach CAE as a separate course. Its integrated with everything, from solid mechanics and heat transfer to fluid mechanics.
Cornell Universitys SimCafe.org features a collection of simulation tutorials based on ANSYS software. The content is distributed via Creative Commons licensing. Its an e-learning portal to integrate industry-standard simulation tools into courses
and to provide a resource for supplementary learning outside the
classroom, according to the site.
I floated through quite a few toolsets in my career, everything from ANSYS to Abaqus [simulation package from Dassault Systmes], says Mannisto. Generally, the concept of constraints and loads where to hold the model, where to put the
load, what a good quality mesh is thats all the same. Those
are the skills not the peculiarities of specific software.
Mannisto looks at FIRST Robotics Programs as fertile
ground for talent scouting. Here, throughout a series of robotic
contests, Mannisto gets to observe how students with a knack for
tinkering work together to solve their electrical, mechanical and
software engineering conundrums. Its like getting to interview
a kid over the course of four [to] five years, he says.

Software as Learning Platforms

In a commentary for DE (Make CAE Mainstream,


deskeng.com/de/?p=25211), Mannisto expressed his opinion.
He wrote: It is my belief that there is too much emphasis on
the inner workings of a computer program and not enough on
the practical application. He recommended, Teach CAE not
as a course, but instead build it into the entire curriculum. Teach
the beam equation, teach Mc/I, then apply it using finite element analysis. Teach continuity, momentum and Navier-Stokes,
then show how to define an entrance condition and a pressure
boundary in a computational fluid dynamics program.
Bhaskaran says studying the software can be an education unto

92%

of traditional STEM jobs


in 2018 will be for those
with at least some postsecondary education and training.

Georgetown University Center on Education


and the Workforces STEM report

itself. You can use the software to teach the underlying math by
relating it to user inputs and outputs. For instance, by meshing
the model, the user is marking out the points where she or he
would like the tool to compute displacements directly and is also
setting the number of algebraic equations that need to be solved.
ANSYS Lethbridge said, What Dr. Bhaskaran does is to use
the black box and then teaches students to probe that black box so
they understand whats going on and how to interpret the results.
You dont need to know how to code, but you need to know
how the tool is taking differential equations and converting them
into algebraic equations. What strategies does it use? What are
the errors introduced in that process? What is it calculating directly and whats derived through post-processing? When you do
something in the software, you should know if youre affecting
the boundary conditions, the governing equations, the numerical
solution strategies or post-processing, Bhaskaran says.
The different views on how to treat the black box are not so
far apart. In the end, both the hiring managers and the educators want the same thing: Aspiring engineers who can use the
black box correctly. If theres a gap between the two sides, its
one that can easily be bridged with ongoing dialog.
Bhaskaran points out the crucial distinction between software expertise and engineering skills. The software doesnt
solve the physical problem for you. It solves a mathematical
model of the physical problem. Students need to know what the
mathematical model is the governing equations and boundary conditions as well as the physical principles and assumptions
embedded in the model, he says. DE

Kenneth Wong is DEs resident blogger and senior editor. Email


him at kennethwong@deskeng.com or share your thoughts on this
article at deskeng.com/facebook.
INFO ANSYS: ANSYS.com

Cornell University Sibley School of Mechanical and


Aerospace Engineering: MAE.Cornell.edu

Modelica: Modelica.org
National Instruments: NI.com
UC Berkeley Jacobs Institute for Design Innovation:
JacobsInstitute.Berkeley.edu

Whirlpool: Whirlpool.com
For more information on this topic, visit deskeng.com.

deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

53

Editors Picks

by Anthony J. Lockwood

Each week, Tony Lockwood combs through dozens of new products to bring you the ones he thinks will
help you do your job better, smarter and faster. Here are Lockwoods most recent musings about the
products that have really grabbed his attention.

Cloud-Native 3D CAD Adds 2D Drawings


Onshape is workstation and browser agnostic.
Onshape is a cloud-native, professionalclass 3D CAD design and collaboration
system. Its the brainchild of a lot of
talented people who inspired much of
the design and engineering software
used today.
This update is a full 2D system with
snap points, dimension and annotation

tools as well as standard, projected,


auxiliary and section views. If users need
a kick to get started, Onshape has downloadable drawing templates.
Currently, Onshape is on a three-week
update schedule, so its always improving
often by user request.

MORE deskeng.com/de/?p=26297

XFdtd Integrates with Optenni Lab


Simplify antenna matching circuit optimization workflows.
Remcoms integration brings together
XFdtds Circuit Element Optimizer add-on
module with Optenni Lab. Optenni Lab
provides automatic matching circuit
generation and optimization routines.
Users can send XFdtd simulation
data to Optenni Lab directly. Its a simple
drop-down menu procedure to invoke

Optenni Lab. Optenni Lab optimizes


matching network topologies and
component values based on the
S-Parameter and efficiency results from
the XFdtd simulation. It then returns
a choice of optimized matching circuit
topologies that meet user design criteria.

MORE deskeng.com/de/?p=26547

EPLAN Platform 2.5 Available


The release enhances parts management capabilities.
Version 2.5 of EPLAN Platform takes the
companys project, process and data
management focus further. Among the key
enhancements announced are faster template creation and a new navigator functionality that makes it easier to create and
edit electrical and fluid power engineering
macros. Version 2.5 now also offers page-

and area-specific revision management.


The Harness proD 3D system for wire
harness design is now coupled with EPLAN
Platforms central parts manager. This
provides a single, integrated parts management system over the course of a project.

MORE deskeng.com/de/?p=26658

HP Expands Workstation Portfolio


Its Z240 is available as a tower or single form factor system.
The HP Z240 workstations are an upgrade
to the companys popular HP Z230 workstation with technological improvements
like an integrated M.2 slot for expansion
cards and connectors as well as a smaller,
more efficient motherboard. The harddrive cage in the HP Z240 SFF (single form
factor) has been re-engineered to provide

54

DE | Technology for Optimal Design Engineering

December 2015 /// deskeng.com

more efficient airflow.


The workstations accommodate up to
64GB of memory and a pair of HPs new Z
Turbo Drive SSDs (solid state drives). They
run 64-bit Windows or Linux, support eight
USB 3.0 ports, Intel processors, as well as
AMD or NVIDIA graphics.

MORE deskeng.com/de/?p=26797

Fast Apps

Engineering Case Studies

A Hands-on Look at Product


Design and Development

DFMA tools from Boothroyd Dewhurst give one college student


a firm grasp of the principles of product design and costing.

atrick Bright was camping with


friends in Northern Arizona
when he came up with the idea for
his class project. An engineering student at Embry-Riddle Aeronautical
University in Prescott, AZ, Bright was
in his junior year and had recently
signed up for course ME 428: Design for Manufacturing and Assembly (DFMA). It was uncharted
territory for Bright, but based on the syllabus he figured it would
be a good way to learn more about manufacturing, a topic hed
long been interested in. He wasnt disappointed.
Before applying for admission to Embry-Riddle, Bright
served in the Marine Corps. Through it all he had his sights set

Simulation Success

on a career in aerospace engineering, but thought he might not


be talented enough for the grueling academic work required.
Thankfully, he was proven wrong.
As he sat in front of his tent, roasting hotdogs, he noticed
that the bench seat of his 2010 Jeep Wrangler wanted to tip
over and he was concerned about rocks and dirt getting into
the connectors on the bottom of the seat.
And so the focus for Brights DFMA class project was born.
Following the DFMA process, Bright began to outline the design
requirements for his concept, now dubbed the Outdoor Bench
Seat Attachment.

MORE deskeng.com/de/?p=27120

Advertising Index
Altair Corp.- HyperWorks ............................. 3
ANSYS ........................................................ C2
BOXX Technologies ..................................... 11
CD-adapco .................................................. 19
COMSOL ................................................... C4

NASA relies on Tecplot CFD and post-processing visualization


software to perfect its Orion spacecraft heat shield.

mericas commitment to deep-space exploration has been


reignited. On Dec. 5, 2014, at the Kennedy Space Center
in Florida, NASA conducted the first test flight of the Orion Program, launching a new chapter in human space travel. If all
goes according to plan, the Orion spacecraft will put humans
on an asteroid by 2025 and on Mars in the 2030s.
More than 1,000 onboard sensors recorded every detail
of the flight. Launched aboard a United Launch Alliance
Delta IV Heavy Rocket, Orion circled Earth twice and reached
an altitude of 3,600 miles during the test flight, about 15
times higher than the International Space Station. To one
day accomplish its ultimate mission sending humans to
Mars and bringing them back safely Orion must withstand
extreme speeds, intense radiation and searing temperatures.
To predict temperature and airflow around the heat
shield during re-entry, a team of about 20 engineers
analyzed heat shield materials in NASA Ames Arc Jet
wind-tunnel and then compared
the results with those generated
by CFD (computational fluid
dynamics) simulations. They then
used Tecplot 360 EX as a postprocessor to analyze, visualize and
understand the CFD results.

Epson ........................................................... 1
ICO Mold ................................................... 35
Infolytica Corp. ........................................... 25
Intel - HPC Handbook ............................. 38-41
Intel Corp. - Altair Benchmarking Study .... 16-17
Livermore Software Technology Corp. .......... C3
Measurement Computing Corp. .................... 15
MSI Computer Corp. ................................... 21
NVIDIA ................................................... 22-23
Okino Computer Graphics Inc. ..................... 47
Origin Labs ................................................. 13
Tormach LLC .............................................. 43

H OPTIMAL DESIGN LEADERS H


BOXX Technologies ..................................... 28
CD-adapco .................................................. 29
COMSOL ................................................... 30
Dassault Systmes ........................................ 31
ESTECO SpA .............................................. 32
Rave Computer ............................................ 33

H SPOTLIGHT H

3DX ............................................................ 51
BOXX Technologies ..................................... 51

MORE deskeng.com/de/?p=27125

For the complete application stories visit deskeng.com/de/fastapps


deskeng.com /// December 2015

DE | Technology for Optimal Design Engineering

55

Commentary

by Cees Links

Design Smart Home Services,


Not Connected Things
A

re you designing for the smart home or for the new


Internet of Things (IoT)? We all know its going to
be really, really big.
According to World Economic Forum: By 2020, more
than 5 billion people will be connected, not to mention 50
billion things.
Cisco says: The IoT is a world where up to 50 billion
things (or devices) will be connected to the Internet by
2020; or, the equivalent of six devices for every person on
the planet.
Gartner says: 4.9 billion connected things will be in use in
2015 (up 30% from 2014), 25 billion by 2020.
These organizations are all predicting amazing opportunities for the future growth of the IoT market. It all sounds
quite rosy and bright. However, there is a growing undercur-

Maybe the industry is selling


the wrong thing: a product
instead of a service.
rent of industry grumbling and complaining that the IoT and
smart home revolution seems to be taking a lot longer than it
should. What is the problem? Maybe the industry is selling
the wrong thing: a product instead of a service.

Engineering as a Service

It is time to take a new look at how our technology industry


approaches and markets the potential of the smart home
the smart IoT. By giving consumers, as well as businesses,
governments and corporations, what they want effective
service applications as well as complete managed solutions
instead of DIY things the tech industry can further accelerate the growth of smart technology, thereby making
our lives safer, more efficient and more comfortable all
for less cost.
End users and consumers dont want to resource, purchase, install and program a variety of smart home devices.
They dont want to be concerned with how these various devices will talk to each other, how these devices will
connect to the Internet, and where and how they can be
controlled. Consumers just want working, out-of-the-box
products and services.

56

DE | Technology for Optimal Design Engineering

They also want secure homes. They want locks and alarms
on their doors and windows that can be remotely controlled
and monitored. They want locks that are smart enough to
realize that when no one is home, the doors and windows
should be closed and locked. Smart enough, even, to send
a message to the homeowner asking for permission to lock
the doors and windows, and go ahead and do so when the
homeowner gives the OK.
End users want homes that are comfortable with control
of the air conditioning and heating that are customized to
how they live their lives. When no one is home, the HVAC
does not need to be on, however, it should know the familys
schedule and assess the temperature of the home and the
weather outside to begin making the home comfortable as
the family heads home.
With smart homes, engineers are applying old technology
to emerging applications. These basic sensing and control
technologies have been available for decades. What is new
is the Web connection, and the smartphones and tablets that
can talk to these home systems.
What is needed now are service providers to handle the
installation, maintenance and operation of the system. Yes,
early innovators and earnest DIYers can go to their local
home improvement store and buy and install all of this right
now. But mostly, people just want it to work easily.
So instead of spending all of this time, money and PR to
convince consumers to buy smart home things, the industry
should team up with service providers to enable them to cost
effectively market and manage these systems. Wouldnt you
be happy if a company like Apple or Intel decided to move
into this space instead of just selling products and ran
a smart home for you?
When we buy a car, most consumers really dont care how
the engine works, how the brakes slow down the vehicle, how
the transmission changes gears, or the fuel system adjusts the
gasoline/air mixture. They just want the car to go where they
want it to go. The less interaction, the better.
In the same way, homeowners want a service that makes
their lives safer, more efficient and more comfortable; all for
less cost and with minimal maintenance.
Quit selling things and start selling services. DE

Links is CEO & Founder of GreenPeak, greenpeak.com. You may


send comments to him about this article via de-editors@deskeng.com.

December 2015 /// deskeng.com

14th International
LS-DYNA Users Conference
June 12-14, 2016

Royal Dearborn Hotel


and Convention Center
Dearborn, MI
Welcome
The conference will host a forum for engineers,
professors, students, consultants, industry leaders, and
interested parties to exchange their ideas, and listen to the
latest in industry and academic presentations..
The presenter (1) of the accepted paper will receive a
complimentary (no fee) registration, when they register
using the LSTC Conference Registration, at the Royal
Dearborn Hotel.
Corporate Participation
Platinum, Gold, Silver, Bronze
Conference Dates
Sunday, June 12, 2016: Registration Exhibition Area Reception
Monday, June 13, 2016: Registration Exhibition Area Banquet
Tuesday, June 14, 2016: Registration Exhibition Area Closing
Wednesday & Thursday, June 15 & 16, 2016: Training Classes
Contact Information
Abstracts & papers: papers@lstc.com
Participation, Registration: Marsha Victory, vic@lstc.com
Abstract Submisson
Deadline: November 30, 2015
Length: Approx. 300 words, include figures
Format: 7 x 8, MS Word template provided
Notification
December 31, 2015
Paper Submission
Deadline: March 05, 2016
Length: 3,000 word maximum
Format: 8 x 11 paper, single-spaced
MS Word template provided

Conference
Call For Papers
Applying LS-DYNA and its strongly
coupled integrated solvers:
Acoustics
Aerospace
Automotive
Crashworthiness
Durability
NVH
Ballistics and Penetration
Biomechanics
Civil Engineering
Electromagnetics
Fluid Dynamics
Compressible
ALE (Lagrangian, Eulerian)
CESE
Incompressible
Granular Flow
Heat Transfer
Impact and Drop Testing
Manufacturing Processes
Metal Forming
Modeling Techniques
Nuclear Power
Occupant Safety
Particle Method
Airbag Particle Method
Discrete Elements
Element Free Galerkin
Smooth Particle Hydrodynamics
PrePost Processing
Seismic Engineering
Ship Building

NOW
AVAILABLE

MODEL WITH COMSOL MULTIPHYSICS

BUILD SIMULATION APPS

SHARE WITH COMSOL SERVER

From Model to App to Server

BRING SIMULATION TO EVERYONE


COMSOL Multiphysics and its Application Builder provide you with tools to easily
design a custom interface for your multiphysics applications. Use COMSOL Server
to distribute your apps to colleagues and customers worldwide.
To learn about simulation apps, visit comsol.com.

Copyright 2015 COMSOL. COMSOL, COMSOL Multiphysics, Capture the Concept, COMSOL Desktop, COMSOL Server , LiveLink, and Simulation for Everyone are either registered
trademarks or trademarks of COMSOL AB. All other trademarks are the property of their respective owners, and COMSOL AB and its subsidiaries and products are not affiliated with,
endorsed by, sponsored by, or supported by those trademark owners. For a list of such trademark owners, see www.comsol.com/trademarks